Battery Busbar Welding Rotor for Low-Deflection Pressing
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Solution Overview
Problem
Existing battery manufacturing devices face challenges in efficiently welding multiple busbars to terminals without significant beam deflection due to the high reaction force required, which can lead to beam bending and inefficiency.
Innovation Solution
A manufacturing device with a rotor and pinion gears that disperses the reaction force into translational and torsional forces, reducing deflection by using a shaft with both bending and torsional rigidity, and incorporating springs for even load distribution and positional variation compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a beam supported at both ends is translated and pressed against the pressing pieces to simultaneously press multiple busbars, then the welding efficiency is improved, but the beam will be greatly bent by the reaction force received from the pressing pieces
Solution Approach 1:
The patent converts the static beam structure into a dynamic rotor that rotates about an axis. The rotor receives reaction forces from multiple pressing pieces simultaneously during rotation, dispersing the force into translational and moment components. This dynamic approach allows the rotor to maintain structural integrity while pressing multiple busbars at once, solving both the efficiency and deflection problems.
Solution Approach 2:
The patent introduces a rotational dimension to the pressing mechanism. Instead of moving a beam linearly in one dimension, the rotor rotates about an axis, adding a rotational degree of freedom. This dimensional change allows the system to handle reaction forces more effectively by distributing them across multiple engagement points during rotation, reducing beam deflection while maintaining pressing effectiveness.
2Reliability
If a large force is applied to simultaneously press multiple pressing pieces against busbars, then the welding quality is improved, but the structural requirements for the pressing mechanism become more stringent
Solution Approach 1:
The rotor design allows the pressing mechanism to dynamically distribute large forces across multiple engagement points during rotation. The rotational motion enables the structure to handle high reaction forces by converting them into manageable translational and moment components, maintaining welding quality without requiring excessive structural strength.
Solution Approach 2:
The pressing mechanism is segmented into multiple discrete pressing pieces engaged with the rotor at different positions. Each pressing piece handles a portion of the total force, distributing the load across multiple contact points. This segmentation allows the application of large total force while reducing the stress on any single structural element.
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
Enables efficient simultaneous pressing of multiple busbars against terminals, reducing beam deflection and ensuring consistent welding pressure, thereby improving the manufacturing process for assembled batteries.
Implementation Method 1
the reaction force of the force that pushes the pressing pieces is received by the bending rigidity and the torsional rigidity of the rotor
Implementation Method 2
the reaction force of the force that pushes the pressing pieces is received by the bending rigidity and the torsional rigidity of the rotor
Implementation Method 3
The spring has elasticity in a circumferential direction of the shaft. A load is evenly applied to each busbar even if there are positional variations of the busbars in the second direction.
Data Source
AI summary
An assembled battery includes a plurality of battery cells stacked in a first direction, each battery cell including a terminal on a surface facing a second direction that intersects the first direction, and a busbar being welded to the terminal. A manufacturing device includes: a plurality of pressing pieces arranged along the first direction, a tip of each of the pressing pieces in the second direction facing the respective terminal with the busbar interposed between the pressing piece and the terminal; a rotor that extends along the first direction and that is rotated by an actuator, the rotor being engaged with the pressing pieces and being configured to press the pressing pieces against the busbars when rotated about an axis; and a welder that welds the busbars and the terminals. The welder welds the busbars to the terminals while the rotor presses the busbars against the terminals.