Busbar Frame Fixing Holes for Accurate Battery Module Welding
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Solution Overview
Problem
In the assembly process of conventional battery modules, the motion of the busbar frame assembly during welding can lead to reduced accuracy and quality of welding, resulting in poor connections between electrode leads and busbars.
Innovation Solution
The battery module incorporates a busbar frame assembly with fixing jig holes on its top and bottom surfaces, allowing welding jigs to be inserted to securely fix the assembly, preventing motion and ensuring stable electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the busbar frame assembly is not fixed during welding, then the welding process can be performed freely, but the accuracy and quality of welding deteriorates due to motion of the busbar frame assembly
Solution Approach 1:
The busbar frame assembly is fixed to the welding jig before the welding process begins. The fixing jig holes are prepared in advance on the busbar frame assembly, allowing welding jigs to be inserted and secured prior to welding, thereby preventing motion during the welding process and ensuring welding accuracy.
Solution Approach 2:
A welding jig serves as an intermediary tool between the busbar frame assembly and the welding electrode. The welding jig includes fixing holes that receive fixing members, creating a stable intermediate platform that prevents direct motion of the busbar frame assembly during welding, thus improving welding precision without requiring permanent structural modifications.
2Reliability
If the busbar frame assembly moves during welding, then the assembly process is simpler without fixing mechanisms, but the connection quality between electrode leads and busbars deteriorates
Solution Approach 1:
The busbar frame assembly is secured to the welding jig before welding begins. The fixing jig holes are pre-positioned on the busbar frame assembly, allowing welding jigs to be inserted and firmly fixed in advance, ensuring stable electrical connection quality during the welding process without requiring complex permanent fixing mechanisms.
Solution Approach 2:
The welding jig acts as an intermediary device that provides stable fixation during welding. By inserting fixing members into the fixing jig holes of the welding jig, the busbar frame assembly is reliably held in position, ensuring high connection quality between electrode leads and busbars while keeping the fixing mechanism simple and removable.
Data Source
AI summary
A battery module according to an embodiment of the present disclosure includes a plurality of battery cells, a busbar frame assembly supporting the plurality of battery cells and including a plurality of busbars electrically connected to electrode leads of the plurality of battery cells, and a plurality of fixing jig holes provided in top and bottom surfaces of the busbar frame assembly, and into which welding jigs for fixing the busbar frame assembly are configured to be inserted in a welding process for electrically connecting the electrode leads of the plurality of battery cells to the plurality of busbars.