Cell Contacting System Positioning Element for Electrochemical Devices
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cell contacting systems face challenges in maintaining the ideal welding position of cable ends during the assembly of electrochemical devices due to low flexural strength, leading to increased cycle times and costs due to the need for repeated alignment and correction processes.
Innovation Solution
The introduction of an additional positioning element on the signal line system side, which is fixed to at least one signal line and electrically connected to a cell connector or power connection, allowing for precise positioning and fixation using ultrasonic welding, thereby eliminating the need for repeated alignment and correction processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If cable ends are used for electrical connection, then electrical conductivity is achieved, but flexural strength is insufficient causing position instability during transport and assembly
Solution Approach 1:
A positioning element is introduced as an intermediary component between the cable end and the carrier element. This positioning element provides the necessary mechanical strength and structural stability to maintain the cable end's position during transport and assembly, while the cable end itself retains its electrical conductivity function. The positioning element acts as a mediator that separates the mechanical support function from the electrical connection function.
2Ease of operation
If cable ends are made flexible for handling, then ease of operation is improved, but manufacturing precision deteriorates due to inability to maintain predetermined position tolerance
Solution Approach 1:
The system is segmented into distinct functional components: the flexible cable end for electrical connection and the rigid positioning element for precise positioning. The cable end can be made flexible and easy to handle, while the positioning element provides the necessary structural rigidity to maintain predetermined position tolerance during welding and assembly operations. This segmentation allows each component to optimize its properties for its specific function.
3Manufacturing precision
If alignment and correction processes are performed repeatedly, then manufacturing precision is improved, but productivity deteriorates due to increased cycle times
Solution Approach 1:
The positioning element is designed to pre-establish the correct position and orientation of the cable end relative to the carrier element before assembly operations begin. This preliminary positioning action eliminates the need for repeated alignment and correction processes during welding and assembly, as the cable end is already in the correct position due to the positioning element's structural design. This significantly reduces assembly cycle time while maintaining high manufacturing precision.
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
This solution simplifies the assembly process by maintaining a defined joining position, reducing tolerance chains, and ensuring higher connection quality without the need for additional control and alignment work, thus reducing cycle times and costs.
Implementation Method 1
the positioning element on the signal line system side is latched with the positioning element on the carrier element side in such a way that the positioning element on the signal line system side in a desired position relative to a cell connector of the power line systems is positioned
Implementation Method 2
These cable ends are welded to the associated cell connector in an assembly plant, for example using an ultrasonic welding process
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention aims to provide a cell contacting system for an electrochemical device, which electrochemical device comprises a plurality of electrochemical cells and a current line system, wherein the cell contacting system comprises a signal line system having one or more signal lines for electrically connecting one signal source each to a signal line connection or to a monitoring device of the cell contacting system and comprises a supporting element, which supports the signal line system, in which cell contacting system an electrically conductive connection can be established between the signal line system and the cell connectors and/or current connections of the current line system in a particularly simple and reliable manner and, to the extent possible, without monitoring and correcting processes after a positioning process. In order to achieve said aim, according to the invention the cell contacting system comprises at least one signal-line-system-side positioning element, which is fastened to a signal line of the signal line system, and at least one supporting-element-side positioning element, which is fastened to the supporting element at least at times, wherein the signal-line-system-side positioning element is connected to the supporting-element-side positioning element at least at times in such a way that the signal-line-system-side positioning element is positioned in a desired position in relation to a cell connector or a current connection of the current line system.