Battery Cell Block Insertion Assembly for Tight Case Tolerances
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Solution Overview
Problem
The assembly of cell-to-pack (CTP) structure batteries faces challenges due to insufficient assembly tolerance between the case and the cell block, making it difficult to maintain constant surface pressure, which complicates the assembly process and increases costs and labor.
Innovation Solution
An automated battery assembly machine is designed with a gripper system that grips and conveys cell blocks, using a pusher to apply pressing force and insert the cell blocks into a case, ensuring accurate alignment and press-fitting without additional support, thereby simplifying the assembly process and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated assembly is implemented, then productivity is improved, but assembly tolerance control deteriorates
Solution Approach 1:
A positioning plate is introduced as an intermediary component between the automated gripper and the cell block. The positioning plate provides mechanical guidance and constraint features that ensure precise positioning of the cell block during automated insertion, bridging the gap between automated handling and precision requirements.
Solution Approach 2:
The system employs adjustable positioning features on the positioning plate that can be modified to accommodate different cell block dimensions and tolerances. This allows the automated assembly system to adapt to varying precision requirements by changing the geometric parameters of the positioning elements.
2Stability of the object's composition
If additional support components are used, then assembly stability is improved, but device complexity increases
Solution Approach 1:
The positioning plate combines multiple functions into a single component: it serves as both a support structure and a positioning mechanism. By integrating positioning features directly into the support plate, the design eliminates the need for separate positioning devices, thereby reducing overall system complexity while maintaining assembly stability.
Solution Approach 2:
The positioning plate is designed with universal features that can accommodate different cell block configurations. The same component provides both mechanical support and precise positioning across various assembly scenarios, reducing the need for multiple specialized parts and simplifying the overall device architecture.
Data Source
AI summary
A battery assembly machine includes a gripper configured to be movable and to double grip a cell block in which a plurality of cells is stacked, and a pusher configured to provide pressing force for inserting the cell block gripped by the gripper into a case.