Bus Bar Reference Marks for Precise Battery Tab Welding
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Solution Overview
Problem
Existing battery module manufacturing processes face challenges in achieving high-quality welding between electrode tabs and bus bars, which is crucial for the reliability and efficiency of electric vehicle battery packs.
Innovation Solution
The proposed solution involves a battery module design with a bus bar structure that includes reference marks for precise alignment and welding, coupled with an apparatus and method that utilize a vision sensor and controller to accurately determine the start point for welding based on these reference marks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional welding processes are used without reference marks, then the manufacturing process is simpler, but the welding precision and alignment between electrode tabs and bus bars deteriorate
Solution Approach 1:
Reference marks are pre-formed on the bus bar surface before the welding process. These marks serve as predetermined alignment indicators that guide the welding operation, ensuring precise positioning of the electrode tabs relative to the bus bar holes without requiring complex real-time adjustment mechanisms during welding.
Solution Approach 2:
The reference marks act as an intermediary element between the bus bar structure and the welding process. By providing visual or detectable markers on the bus bar surface, they mediate the alignment process, enabling the welding system to accurately locate and weld electrode tabs to the correct positions on the bus bar.
2Reliability
If manual alignment methods are used for welding, then the equipment is simpler, but the welding quality and reliability deteriorate
Solution Approach 1:
The patent replaces manual mechanical alignment methods with an automated vision-based detection system. The apparatus includes sensors or cameras that detect the reference marks on the bus bar, and a controller that processes this information to automatically determine welding start positions, eliminating the need for manual measurement and alignment operations.
Solution Approach 2:
The welding apparatus incorporates a feedback mechanism where the vision sensor detects the actual position of reference marks on the bus bar, the controller processes this information to determine the precise welding start position, and this information feeds back to adjust the welding operation. This closed-loop system ensures high welding reliability by compensating for any positional variations.
3Measurement precision
If reference marks are added to the bus bar, then the welding accuracy improves, but the manufacturing complexity of the bus bar increases
Solution Approach 1:
The reference marks are formed on the bus bar during the bus bar manufacturing process itself, before the battery assembly operations. This preliminary formation of marks integrates the marking step into the existing manufacturing workflow, minimizing additional complexity. The marks can be created using standard manufacturing techniques such as embossing, machining, or marking during the extrusion or forming of the bus bar.
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 enhances the quality and accuracy of the welding process, leading to improved reliability and performance of battery modules in electric vehicles and other green technology applications.
Implementation Method 1
a vision sensor configured to create an image by photographing a state in which the electrode tab of the battery cell is inserted in the bus bar
Implementation Method 2
A bus bar and an electrode tab can be welded using laser welding of various types of welding
Data Source
AI summary
Proposed is an apparatus for manufacturing a battery module that welds at least one electrode tab of a plurality of battery cells and at least one bus bar that are included in the battery module, the apparatus including a vision sensor configured to create an image by photographing a state in which the electrode tab of the battery cell is inserted in the bus bar, and a controller configured to recognize a first reference mark formed close to the hole of the bus bar in the image and determine a start point for welding the bus bar and the electrode tab on the basis of the first reference mark. Since the apparatus determines a start point of welding by recognizing a reference mark formed on a bus itself, it is possible to determine a welding position regardless of variation of lamps or the surrounding environment.