Bus Bar Through-Hole Geometry for Battery Weld Detection
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Solution Overview
Problem
Existing battery pack configurations struggle to accurately determine the welding location between bus bars and battery cells through image analysis, especially when only two sides of the bus bar are present around the through hole, leading to difficulties in assessing the appropriateness of the welding.
Innovation Solution
The battery pack and bus bar configuration include a hexagonal-shaped through hole in the bus bar, which allows for the recognition of the welding location by image analysis regardless of the bus bar shape, ensuring accurate assessment of the welding quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If only two sides of the bus bar are present around the through hole, then the bus bar structure is simpler, but the welding location cannot be detected by image analysis
Solution Approach 1:
The through hole is designed with an asymmetric configuration where three sides of the bus bar are present around the through hole, with at least one corner portion formed by intersecting sides. This asymmetric structure provides sufficient reference edges for image analysis to detect and estimate the welding location, resolving the detection difficulty while maintaining structural simplicity
2Adaptability or versatility
If the bus bar shape varies by position, then the bus bar can be adapted to different locations, but the welding location cannot be consistently detected by image analysis
Solution Approach 1:
The through hole design with three surrounding sides and corner portions serves as a universal reference structure that can be consistently identified by image analysis regardless of the bus bar's overall shape or position. This universal feature enables consistent welding location detection across different bus bar configurations and positions
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 configuration enables reliable image-based recognition of the welding location, improving the efficiency of quality checks and ensuring consistent and appropriate welding between bus bars and battery cells.
Implementation Method 1
After the welding, an image analysis is performed onto the welding portion so as to determine whether or not the welding has been appropriately performed
Data Source
AI summary
Each of a first battery cell and a second battery cell included in a battery pack includes an electrode terminal, a first bus bar includes a connection portion having a strip shape, the connection portion having both sides parallel to each other and each extending in an X axis direction, and the connection portion is provided with a through hole used for joining to the electrode terminal by welding, the through hole has a hexagonal shape formed by sequentially connecting a first corner portion, a second corner portion, a third corner portion, a fourth corner portion, a fifth corner portion, and a sixth corner portion, and an imaginary straight line connecting the first corner portion and the fourth corner portion is perpendicular to each of the both sides.