Battery Module Pre-Stacking Mechanism for Mixed Row Configurations

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Solution Overview

Problem

Existing pre-stacking mechanisms for battery modules struggle to efficiently accommodate both double-row and single-row battery cells with different specifications, leading to inefficiencies in battery production lines.

Innovation Solution

A pre-stacking mechanism comprising a multi-row and single-row pre-stacking mechanism disposed on a workbench, equipped with features like centering clamping, fixed end positioning, and movable end limiting mechanisms, allowing for adaptable alignment and support of various battery cell configurations without requiring adjustments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a single pre-stacking mechanism is used for both double-row and single-row battery cells, then device complexity is reduced, but manufacturing precision and adaptability deteriorate

Engineering Contradiction:

Improvepre-stacking mechanism structureVSAvoidalignment precision

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The pre-stacking mechanism is divided into two independent subsystems: a single-row pre-stacking mechanism and a multi-row pre-stacking mechanism. Each subsystem is optimized for its specific battery cell configuration, ensuring high alignment precision without requiring a complex universal design. The segmentation allows each mechanism to be tailored to its specific stacking requirements while maintaining overall system simplicity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Both pre-stacking mechanisms share common structural components and control systems, allowing them to be integrated into a unified platform. The mechanisms can handle different battery cell types (lithium iron phosphate, ternary, nickel-cadmium) and configurations (single-row, double-row, triple-row) through standardized interfaces and adjustable parameters, achieving versatility without significant complexity increase.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If the pre-stacking mechanism is adjusted for different battery module models, then adaptability improves, but loss of time increases

Engineering Contradiction:

Improveadaptation to different battery modelsVSAvoidadjustment time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The pre-stacking mechanisms incorporate dynamically adjustable components including variable-speed motors, programmable control systems, and movable positioning elements. These dynamic features allow rapid reconfiguration between different battery module models through automated control, eliminating manual adjustment operations and reducing changeover time while maintaining full adaptability to various cell configurations.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The control system stores standardized stacking parameters and configurations for different battery module models. When switching between models, the system automatically retrieves and applies pre-programmed parameters, effectively copying successful configurations rather than requiring重新 adjustment. This digital replication approach maintains adaptability while minimizing adjustment time.

Inventive Principle:

Principle #26Copying

3Manufacturing precision

If separate pre-stacking mechanisms are used for single-row and multi-row battery cells, then manufacturing precision improves, but device complexity increases

Engineering Contradiction:

Improvealignment precisionVSAvoidpre-stacking mechanism structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The single-row and multi-row pre-stacking mechanisms are merged into an integrated system sharing common structural elements including the workbench, control system, power supply, and safety monitoring infrastructure. The specialized stacking components are modular units that can be independently optimized for their specific functions while benefiting from the shared platform, reducing overall complexity compared to completely separate systems.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Each pre-stacking mechanism is designed with local optimizations tailored to its specific function: the single-row mechanism features specialized alignment guides and clamping structures for individual cell precision, while the multi-row mechanism incorporates coordinated positioning systems for multiple cells. These localized quality enhancements achieve high manufacturing precision without requiring the entire system to be overly complex.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS20250253471A1Pre-stacking mechanism for battery module and battery production line

Publication Date: 2025.08.07 CONTEMPORARY AMPEREX TECHNOLOGY (HONG KONG) LIMITED

AI summary

A pre-stacking mechanism for battery module and a battery production line are described. The pre-stacking mechanism for battery module includes a workbench, a multi-row pre-stacking mechanism, and a single-row pre-stacking mechanism. The multi-row pre-stacking mechanism is configured to pre-stack multi-row battery cells to form a multi-row battery module. The single-row pre-stacking mechanism is configured to pre-stack single-row battery cells to form a single-row battery module. Both the single-row pre-stacking mechanism and the multi-row pre-stacking mechanism are disposed on the workbench. The pre-stacking mechanism for battery module in the embodiments of this disclosure can improve the efficiency of the battery production line.