Cell Stack Positioning Jaws for Fast Electrode Alignment
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Solution Overview
Problem
The existing methods for manufacturing lithium-ion battery cell stacks are complex, unreliable, and not suitable for rapid series production due to the need for precise electrode positioning and alignment of differently sized components.
Innovation Solution
A device with positioning units and a moving unit that oscillates or vibrates to center and align cell assemblies or plies, using air nozzles for alignment and a decoupled support to maintain stability, allowing for quick and simple assembly of cell stacks with varying dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional stacking methods with manual positioning and vacuum grippers are used, then electrode positioning can be achieved, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The cell assembly utilizes its own geometric features (edges, corners, or specific markers) to automatically define its position on the support surface. The positioning method requires no external active actuators, sensors, or complex control systems - the assembly self-aligns through its interaction with the support surface geometry, thereby achieving precise positioning while eliminating complex handling devices
Solution Approach 2:
The invention extracts and eliminates the complex vacuum gripper and active positioning control systems from the manufacturing process. By using passive geometric positioning features inherent to the cell assembly and support surface, the patent removes unnecessary complex components while maintaining positioning accuracy
2Stability of the object's composition
If workpiece supports with integrated hold-down devices are used to fix cell assemblies, then positioning stability is improved, but the device complexity and manufacturing time increase
Solution Approach 1:
The cell assembly's own geometric features serve as the positioning and stabilization mechanism. By designing the support surface with corresponding geometric features that match the cell assembly features, the system achieves stable positioning without requiring integrated hold-down devices, active actuators, or complex control systems
Solution Approach 2:
The invention removes integrated hold-down devices and active positioning actuators from the support structure. Stability is achieved through passive geometric interlocking between the cell assembly features and support surface features, eliminating complex mechanical stabilization systems
3Manufacturing precision
If image processing and automatic placement are used for cell assemblies, then positioning accuracy is improved, but the manufacturing speed and simplicity are reduced
Solution Approach 1:
The cell assemblies are pre-equipped with geometric positioning features during manufacturing that directly correspond to features on the support surface. This preliminary design of complementary geometric features enables direct visual alignment and placement without requiring image processing analysis or complex computational positioning calculations during assembly
Solution Approach 2:
The geometric features on the cell assemblies and support surface enable the system to self-align and self-position through simple visual inspection. The features naturally guide correct placement through their geometric complementarity, eliminating the need for active image processing systems and computational control
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 rapid, reliable, and efficient manufacturing of cell stacks, particularly suitable for series production, by ensuring precise alignment and firm connection of components, even with different sizes, thus improving the manufacturing process's simplicity and scalability.
Implementation Method 1
a first moving unit configured for moving the positioning units... The actuator is configured for moving, in particular vibrating, the moving plate
Implementation Method 2
the device comprises at least one air nozzle configured for providing an air flow, wherein the air nozzle, due to the air flow, is configured for aligning the cell assemblies and/or plies
Implementation Method 3
a support, wherein the plurality of cell assemblies and/or plies rest on the support, wherein the support is decoupled from the movement of the first moving unit
Data Source
AI summary
A device for manufacturing a cell stack having a plurality of cell assemblies. The device comprises several positioning units accommodating the plurality of cell assemblies. The positioning units each comprise a positioning jaw enclosing the plurality of cell assemblies disposed one above the other. The device further comprises a first moving unit moving the positioning unit. The first moving unit comprises a moving plate mounted in a movable manner and an actuator. The positioning units are disposed on the moving plate. The actuator moves the moving plate. The positioning units are arranged such that the individual cell assemblies are centered between the positioning jaws by the movement initiated by the first moving unit. Finally, the device comprises a support, which is decoupled from the movement of the first moving unit, wherein the plurality of cell assemblies and/or plies rest on the support.