Multi-Level Battery Pack Assembly with Parallel Module Positioning
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Solution Overview
Problem
Existing battery module assembly techniques for electric vehicles are prone to errors due to extended tolerance chains and complex module positioning, leading to inefficiencies and increased production times, particularly when forming multi-level configurations.
Innovation Solution
A production apparatus with parallel processing lines and transport devices for simultaneous handling of battery components, allowing precise and rapid assembly of side-by-side and overlapping modules using trolleys or conveyors, with integrated assembly stations for seamless integration and adaptability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If modules are assembled sequentially level by level, then the assembly process can be completed, but the tolerance chain extends and positioning errors accumulate
Solution Approach 1:
The assembly process is segmented into parallel assembly lines, each handling specific levels. Multiple levels are assembled simultaneously on different lines rather than sequentially, breaking the extended tolerance chain into separate parallel processes that don't accumulate errors.
Solution Approach 2:
The patent introduces a temporal dimension by assembling multiple levels simultaneously in parallel rather than sequentially in a single line. This transforms the process from a linear sequence to a multi-dimensional parallel operation, reducing the cumulative effect of tolerances.
2Productivity
If multiple levels are assembled simultaneously in parallel, then production efficiency increases, but the complexity of coordinating transport and positioning increases
Solution Approach 1:
The transport devices are designed as universal, modular units that can handle different battery modules and levels. Each transport device performs multiple functions: transporting modules, positioning them precisely, and coordinating with assembly stations. This multi-functionality reduces the need for specialized equipment for each task.
Solution Approach 2:
The transport devices act as intermediaries between the module supply and assembly stations. They coordinate the timing and positioning of modules being assembled on different levels, mediating the complex synchronization requirements through a standardized interface and control system.
3Measurement precision
If the assembly apparatus is highly automated, then precision and speed improve, but the cost and complexity of implementation increase
Solution Approach 1:
The system employs dynamic, adjustable positioning mechanisms on transport devices that can adapt to different module configurations. Rather than fixed, overly complex automation, the system uses controllable, reconfigurable elements that provide precision while maintaining flexibility and reducing unnecessary complexity.
Data Source
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AI summary
An apparatus (A) for assembling a battery pack with a multi-level configuration (B1, B2, B3, B4) made up of several side-by-side and overlapping modules. The apparatus (A) comprises: - a plurality of stations (10, 20, 30, 40) arranged in succession and designed to work or assemble the different modules that form the levels (B1, B2, B3, B4) of the battery pack (B), - a first and a second processing line (1, 2) parallel to each other, each facing a respective side of the stations (10, 20, 30, 40), - a first and a second transport device (3, 4) arranged to transport, along the respective line (1, 2), respectively, a first group of components (C) of the battery pack (B) arranged to form a base level (B1) of said multi-level configuration, and a second group of components (C') of the battery pack (B) arranged to form successive levels (B2, B3, B4) to be overlapped on the base level (B1). The apparatus (A) also comprises a joining station (40) of the levels (B1, B2, B3, B4) configured to assemble said second group of components (C') above said first group of components (C), so to produce said multi-level configuration of the battery pack (B).