Battery Stack Forming Apparatus with Optical Position Correction

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Solution Overview

Problem

The existing battery stack forming methods face challenges in maintaining accurate positioning of electrode tabs and busbars during laser welding, leading to variations in welding quality due to clearances between spacers and positioning members.

Innovation Solution

A battery stack forming apparatus and method that utilize a stacking robot, detection unit, and control unit to accurately position reference portions on the electrode tabs by correcting their attitude against a reference block, ensuring precise alignment with stacking reference positions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If spacers with positioning members are used to stack electric cells, then the electric cells can be stacked with support and connection, but clearances between positioning members cause positional variation

Engineering Contradiction:

Improvestacking operationVSAvoidpositioning precision

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The patent replaces the mechanical positioning system (spacing members with physical clearances) with an optical detection and control system. Cameras detect the positions of reference portions on electrode tabs, and the control unit calculates correction amounts to adjust robot positioning, thereby eliminating the impact of mechanical clearances on positioning precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent implements a feedback mechanism where the detection unit (cameras) continuously monitors the positions of reference portions on electrode tabs during stacking. The control unit uses this feedback information to calculate and apply real-time correction amounts to the robot's positioning, ensuring accurate alignment despite mechanical clearances in the spacer system.

Inventive Principle:

Principle #23Feedback

2Ease of manufacture

If clearances are present between coupling holes and coupling pins, then assembly is easier, but positional variation occurs in electric cells

Engineering Contradiction:

Improveassembly easeVSAvoidpositioning precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent replaces reliance on mechanical fitting precision (coupling holes and pins) with an optical detection and robotic control system. The cameras detect reference portions on electrode tabs, and the control unit adjusts robot positioning based on detected positions, thereby compensating for clearances in the mechanical coupling system.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces reference portions on electrode tabs as intermediary detection targets. These reference portions serve as mediators between the mechanical assembly system and the optical detection system, allowing precise position measurement without being affected by clearances in the coupling hole-pin interface.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If electrode tab position is not precisely controlled, then stacking is simpler, but welding quality varies

Engineering Contradiction:

Improvestacking speedVSAvoidwelding quality

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent performs preliminary detection of electrode tab positions using cameras before the stacking operation. The control unit calculates correction amounts in advance based on detected positions, allowing the robot to pre-position the electric cells accurately before welding, thereby ensuring welding quality without reducing stacking speed.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent implements real-time feedback during the stacking process where cameras detect reference portions on electrode tabs, and the control unit continuously monitors and adjusts robot positioning. This feedback mechanism ensures that electrode tab positions are precisely controlled throughout stacking, maintaining consistent welding quality while preserving high productivity.

Inventive Principle:

Principle #23Feedback

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 approach stabilizes the welding quality by reducing positional variations of electrode tabs and busbars, enabling consistent and high-quality laser welding in the battery stack.

Implementation Method 1

a detection unit that detects positions of reference portions set in at least two locations on the electrode tab

Methodology Applied

Scientific EffectOptical detection: Photography

Implementation Method 2

a stacking robot that holds and stacks each of the electric cells

Methodology Applied

Scientific EffectMechanical force: Mechanical Force

Implementation Method 3

The control unit holds, using the stacking robot, each of the electric cells, detects, using the detection unit, the positions of the reference portions

Methodology Applied

Scientific EffectPositioning control:

Data Source

PatentUS11411286B2Battery stack forming apparatus and battery stack forming method

Publication Date: 2022.08.09 ENVISION AESC JAPAN LTD

AI summary

To provide a battery stack forming apparatus and a battery stack forming method that are capable of stacking electric cells with the electric cells accurately maintained in positions.