Battery Pack Bus Bar Positioning Marks for Accurate Welding
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Solution Overview
Problem
The lack of positioning marks on collector plates for battery packs leads to inaccurate welding, resulting in faulty electrical connections, potential safety hazards, and increased costs due to the need for rewelding or replacing faulty welds.
Innovation Solution
Incorporating a positioning reference mark, such as a recess, on the collector plate's welding part to align with the electrode terminal, allowing for precise welding and inspection, thereby improving alignment accuracy and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If positioning marks are not provided on the collector plate, then the structure remains simple and manufacturing cost is low, but welding positioning accuracy deteriorates leading to faulty electrical connections
Solution Approach 1:
The patent applies preliminary action by pre-forming positioning reference marks (such as recesses or protrusions) on the collector plate during the stamping or forming process, before the welding operation takes place. These marks are prepared in advance to guide the welding head's positioning, ensuring accurate alignment with the battery terminal without requiring complex additional positioning mechanisms.
Solution Approach 2:
The positioning reference mark serves as an intermediary element between the collector plate and the welding head. It provides a reference feature that the welding head can detect and align with, facilitating precise positioning without requiring direct complex mechanical guidance between the collector plate structure and the welding equipment.
2Reliability
If positioning reference marks are added to the collector plate, then welding accuracy improves, but manufacturing complexity and cost increase
Solution Approach 1:
The positioning reference marks are formed during the initial stamping or forming of the collector plate, integrating the positioning feature into the base manufacturing process rather than requiring separate addition steps. This preliminary formation approach minimizes additional manufacturing complexity while ensuring the marks are precisely positioned.
Solution Approach 2:
The patent applies local quality by adding only minimal localized features (small recesses or protrusions) at specific critical locations on the collector plate where welding positioning is needed, rather than modifying the entire collector plate structure. This keeps the overall manufacturing process simple while providing sufficient positioning information locally at the welding interface.
3Productivity
If accurate welding positioning is not achieved, then manufacturing process remains fast, but product quality deteriorates requiring rewelding or replacement
Solution Approach 1:
The positioning reference marks are prepared in advance on the collector plate, allowing the welding head to quickly locate and align with the correct position without requiring complex real-time measurement or adjustment during the welding process. This maintains high welding speed while ensuring accurate positioning.
Solution Approach 2:
The positioning reference marks provide immediate visual or sensor-based feedback to the welding system, enabling the welding head to quickly detect and confirm proper alignment before executing the weld. This feedback mechanism ensures accurate positioning without significantly slowing down the welding operation.
Data Source
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Figure 4a~4b
AI summary
The present invention discloses a collector plate for a battery pack, the collector plate comprising a welding part to be welded to an electrode terminal of a battery unit, wherein the welding part comprises a first side configured to come into contact with the electrode terminal during welding; and a second side opposite to the first side and provided with a positioning reference mark, which is configured as a positioning reference point for welding. By providing a positioning reference mark aligned with an electrode terminal of the corresponding battery unit at the welding part of the collector plate, the positioning accuracy of welding and the quality of the welding of a collector plate and an electrode terminal of a battery unit may be greatly improved, which improves the safety, accuracy, and efficiency of welding operations and avoids potential safety incidents in the circuit of the battery pack, thus increasing the product acceptance rate to reduce the material cost, labour cost, time cost, and total product cost.