Battery Module Cell Block Fixing Structure for Terminal Hole Alignment
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Solution Overview
Problem
The positional accuracy of terminal holes in a cell block assembly is compromised during the welding process of a battery module due to insufficient positional restraint before the thermal resin hardens, leading to misalignment of the terminal holes.
Innovation Solution
A cell block fixing structure using a jig moving body and fixing jigs that are connected to a welding machine, allowing the fixing jigs to be inserted and fitted into terminal holes, with features like a tapered shape and ball joint for rotation, to restrain the cell block assembly from moving during welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal resin is used to restrain the cell block assembly, then the cell block assembly is fixed after hardening, but the positional restraint is insufficient before hardening causing movement during welding
Solution Approach 1:
The fixing jig is inserted into the terminal hole before the welding process begins, establishing positional restraint in advance. The jig moving body is positioned above the module frame before welding starts, and the fixing jig is inserted into the terminal hole to prevent movement during the subsequent welding operation.
Solution Approach 2:
The fixing jig acts as an intermediary tool that transfers and maintains the positional relationship between the terminal hole and module frame during welding. The jig moving body serves as a mediator to apply downward force, ensuring the fixing jig remains properly positioned in the terminal hole throughout the welding process.
2Ease of manufacture
If the cell block assembly is allowed to move freely before thermal resin hardening, then the assembly process is simpler, but the terminal holes become misaligned during welding
Solution Approach 1:
The fixing jig is designed to be self-aligning through its interaction with the terminal hole. The downward movement of the jig moving body automatically positions the fixing jig correctly in the terminal hole without requiring complex external positioning mechanisms, maintaining simplicity while ensuring precision.
3Manufacturing precision
If a rigid fixing structure is used to prevent cell block movement, then positional accuracy is improved, but the device complexity increases
Solution Approach 1:
The fixing mechanism is divided into two functional segments: the jig moving body that provides downward movement and positioning, and the fixing jig that inserts into the terminal hole for restraint. This segmentation allows each component to be simple in design while collectively achieving the required positional accuracy.
Solution Approach 2:
The fixing mechanism incorporates dynamic elements where the jig moving body can move downward to insert the fixing jig into the terminal hole. This dynamic action provides the necessary restraint during welding without requiring a permanently complex rigid structure, as the fixing is activated only when needed.
Data Source
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AI summary
A cell block fixing structure for battery module assembly, including a jig moving body positioned above a module frame when the module frame is placed on a welding machine and fixed, and a fixing jig connected to a lower end of the jig moving body, wherein the cell block assembly includes at least one terminal busbar formed to protrude to the outside of the module frame on one side of the module frame, at least one terminal hole is formed in the at least one terminal busbar is provided. The jig moving body moves downward such that the fixing jig is inserted and fitted into the at least one terminal hole at the time of welding the module frame.