Battery Cell Weld Inspection Using Uniform Tensile Force Feedback
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Solution Overview
Problem
Existing methods for inspecting the coupling strength of weld portions between battery cells are unreliable due to variability in the force applied by workers, leading to inconsistent evaluation of welding strength and potential safety issues.
Innovation Solution
A battery cell weld portion inspection apparatus that includes a coupling portion, a shaft with a spring, a sensor, and a sensing portion, which applies uniform tensile force to the weld portion and senses the movement distance to determine the welding strength accurately.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual pulling method is used to inspect weld portion, then inspection can be performed, but reliability of inspection deteriorates due to variability in worker skill and applied force
Solution Approach 1:
The patent replaces the manual mechanical pulling operation with a controlled mechanical testing apparatus. The apparatus includes a pulling mechanism that applies force through a wire to the weld portion, and a force measurement device that quantifies the coupling strength. This substitution eliminates variability in applied force and provides objective, repeatable measurements of weld strength.
2Measurement precision
If high pulling force is applied to detect weak weld portions, then detection capability is improved, but weld portion may be damaged
Solution Approach 1:
The patent incorporates a force measurement device that provides real-time feedback on the applied pulling force and the resulting weld response. This feedback mechanism allows the testing system to detect the exact point at which the weld fails or shows weakness, enabling precise measurement without applying excessive force that would cause damage. The system can stop or adjust the force application based on the measured response.
3Object-affected harmful factors
If low pulling force is applied during inspection, then weld portion damage is prevented, but weak weld portions cannot be detected
Solution Approach 1:
The patent employs a dynamic testing approach where the pulling force is applied in a controlled manner, allowing the system to progressively load the weld portion until failure or weakness is detected. The force measurement device continuously monitors the applied force and the weld's response, enabling the system to identify the precise force threshold at which the weld fails. This dynamic measurement captures the true strength characteristics without permanently damaging the weld.
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
The apparatus ensures consistent and accurate inspection of weld portions by applying uniform force, improving reliability and preventing damage to the welds during inspection, thereby enhancing the safety and performance of battery cell connections.
Implementation Method 1
a spring means configured to be coupled top a driving portion... The spring means applies initial stress to the tension hook to move the tension hook to the initial position thereof
Data Source
AI summary
A battery cell weld portion inspection apparatus may include a coupling portion configured to be coupled to a connection member coupled to a weld portion of a battery cell, a shaft including a lower end coupled to the coupling portion, a spring disposed around an outer surface of the shaft, a sensor configured to measure a movement distance of the shaft, a sensing portion coupled to an upper end of the shaft, the sensor being configured to measure the movement distance of the shaft based on a position of the sensing portion, and a case configured to receive the shaft, the sensor, and the sensing portion.