Busbar Holder Alignment for Tolerance-Safe Tab Lead Clamping
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Solution Overview
Problem
The challenge of properly clamping busbars to tab leads in battery cells is hindered by positional deviations due to manufacturing tolerances, leading to potential defects and reduced work efficiency during the mounting of busbar holders in cell stacks.
Innovation Solution
A busbar holder mounting method and apparatus that allows busbars to be movable in the X direction relative to the holder, utilizing a comb-shaped comb tooth jig for opening and positioning, followed by controlled mounting and releasing steps to ensure accurate alignment and clamping without interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If busbars are made movable in the X direction relative to the busbar holder during clamping, then the busbars can be easily clamped without difficulty despite positional deviations, but the busbars may relatively move to a position of interference with the tab leads during mounting
Solution Approach 1:
The comb tooth jig performs preliminary actions by opening the tab leads in the X direction before the busbar holder is mounted. This preliminary opening creates sufficient space for the busbars to be positioned without interference, allowing the busbars to remain movable during clamping while preventing interference during mounting.
Solution Approach 2:
The comb tooth jig acts as an intermediary tool that temporarily modifies the tab leads' configuration. By inserting the comb tooth jig between the tab leads and opening them, it mediates the spatial relationship between the tab leads and busbars, enabling both movable clamping and interference-free mounting.
2Productivity
If the busbars are positioned fixedly during mounting, then the work efficiency during mounting is improved, but the busbars become difficult to clamp properly due to manufacturing tolerances
Solution Approach 1:
The busbars are designed to be dynamically movable in the X direction relative to the busbar holder during the clamping operation. This dynamic capability allows the busbars to self-adjust to positional deviations caused by manufacturing tolerances, ensuring proper clamping while maintaining high mounting efficiency through the comb tooth jig's preliminary positioning.
3Productivity
If the tab leads are opened in the X direction before mounting, then the busbars can be arranged without interference, but additional steps are required in the mounting process
Solution Approach 1:
The comb tooth jig combines multiple functions into a single tool: it opens the tab leads in the X direction, positions the busbars, and facilitates their arrangement without interference. By merging these operations into one integrated tool and process step, the solution avoids adding excessive complexity while maintaining high mounting efficiency.
Data Source
AI summary
The busbar holder mounting method includes an opening step, a positioning step, a mounting step, and a releasing step. The busbar holder holds the busbars arranged side by side in the X direction so as to be relatively movable in the X direction. In the opening step, a comb tooth jig is inserted between the tab leads to open the tips of the tab leads in the X direction. In the positioning step, the busbar holder is gripped by a predetermined holder gripper, and the holder gripper is engaged with the plurality of busbars, thereby positioning the busbars in the X direction relative to the holder gripper and the busbar holder. In the mounting step, the busbar holder is mounted to the cell stack. In the releasing step, the positioning of the busbars in the X direction by the holder gripper is released.