Battery Pallet Clamping Assembly for Accurate Cell-to-Lattice Welding
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Solution Overview
Problem
The assembly of battery modules with cylindrical cells is challenging due to their shape and size, leading to inconsistent placement and inaccurate welds between cells and the conductive lattice, which can result in performance issues and failures in battery modules.
Innovation Solution
A battery module manufacturing clamping assembly that includes a pallet base plate with springs and a clamping plate with apertures, a lift system to actuate the pallet base plate, and a method to apply a pre-determined contact force to ensure consistent alignment and contact between battery cells and the conductive lattice for welding, allowing for multiple high-speed welds to be performed sequentially.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a robot is used for welding battery cells to the conductive lattice, then automation and productivity are improved, but weld accuracy and reliability deteriorate due to inconsistent battery positioning
Solution Approach 1:
The patent applies preliminary action by positioning and clamping the cylindrical battery cells to the conductive lattice structure before the welding operation. The fixture system pre-aligns multiple battery cells in a predetermined configuration, ensuring consistent positioning and orientation before the robot performs welding. This preliminary positioning step eliminates the inconsistency that would otherwise cause weld accuracy problems during automated assembly.
2Adaptability or versatility
If laser welding is performed with the welding laser moved between each location, then flexibility is improved, but manufacturing precision deteriorates due to cumulative positioning errors
Solution Approach 1:
The fixture system performs preliminary positioning of all battery cells relative to the conductive lattice structure before welding begins. This pre-alignment establishes a stable reference framework that eliminates cumulative positioning errors that would occur if the laser had to move and reposition between each weld location. The batteries are pre-clamped in precise positions, allowing the welding process to proceed with high consistency.
3Ease of operation
If battery cells are held loosely during assembly, then ease of operation is improved, but manufacturing precision deteriorates due to alignment variations
Solution Approach 1:
The fixture system provides preliminary positioning and clamping of battery cells to the conductive lattice structure before welding. The clamping mechanism secures the cells in precise predetermined positions, eliminating alignment variations that would occur with loose holding. This preliminary fixation maintains both ease of operation during placement and high manufacturing precision during welding.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution ensures accurate and consistent welds, improving the quality and reliability of battery modules by maintaining precise contact force and alignment, thereby enhancing the assembly process and reducing the risk of module failure.
Implementation Method 1
a pre-determined contact force is applied to the battery cells by the plurality of springs
Data Source
AI summary
The present disclosure provides battery module manufacturing clamping assembly and a method of clamping a battery pallet for welding. According to the present disclosure, a battery module manufacturing clamping assembly comprises a pallet assembly, a clamping plate, and a lift system for actuating the pallet assembly with respect to the clamping plate. The pallet assembly comprises a spring under each battery cell in the battery pallet, and the battery pallet can be actuated by the lift system into a clamped position where the pallet base plate and the clamping plate cause a top portion of the plurality of battery cells to be in contact with the conductive lattice structure for welding, and wherein a pre-determined contact force is applied to the battery cells by the plurality of springs.