Magnetic Busbar Alignment for Laser Welding
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Solution Overview
Problem
Ensuring secure and efficient electrical connections between busbars and battery terminals in large battery modules is challenging due to vibration, temperature changes, and the need for planar contact in laser welding, which can be difficult to achieve without mechanical fixtures.
Innovation Solution
A magnetic force is used to align and secure the busbar or terminal tab to the battery terminal, allowing for precise planar contact and subsequent laser welding, utilizing a magnetic field to push or pull the tab onto the terminal, and a jig to guide the process, ensuring consistent contact and high-quality welds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical fixtures are used to ensure planar contact for laser welding, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent replaces mechanical fixtures with a magnetic field generation system. Electromagnets or permanent magnets are used to generate magnetic forces that press the busbar against the battery terminal, eliminating the need for complex mechanical clamping fixtures while achieving the required planar contact precision for laser welding.
Solution Approach 2:
The patent changes the physical state or condition by introducing magnetic field parameters (field strength, distribution, and control) to achieve contact pressure and alignment. This substitution of mechanical parameters with magnetic field parameters simplifies the overall system while maintaining manufacturing precision.
2Ease of operation
If magnetic force is used to align and secure the busbar, then ease of operation is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent uses magnetic fields to replace manual or mechanical alignment operations. The magnetic force automatically draws and positions the busbar against the terminal, making the alignment process easier while the controlled nature of magnetic fields ensures consistent contact planarity.
Solution Approach 2:
The magnetic field acts as an intermediary between the power source and the busbar, providing both the force for alignment and the pressure for secure contact. This intermediary enables easy operation while maintaining precision through field control rather than direct mechanical intervention.
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 method enhances the reliability and efficiency of busbar connections by ensuring secure, planar contact and high-quality welds, improving the operational safety and efficiency of battery modules by maintaining contact integrity despite mechanical stresses and variations.
Implementation Method 1
A magnetic force is used to align and secure the busbar or terminal tab to the battery terminal, allowing for precise planar contact and subsequent laser welding, utilizing a magnetic field to push or pull the tab onto the terminal
Data Source
AI summary
Methods and systems for welding a terminal of a battery cell to corresponding terminal tab or busbar are described using a magnet that causes the terminal and tab/busbar to be placed in physical contact. The terminal of a battery cell is aligned in contact with the tab/busbar by the force of a magnetic field. A welder, e.g., a laser welder, can then generate a laser weld beam to weld the terminal of the battery cell to the tab/busbar. Next, the laser weld beam is narrowed, reducing the first diameter to a smaller second diameter. Without touching the tab/busbar or terminal of the battery (which could affect the welding operation), the magnetic field can cause a force that brings the tab and terminal in contact during welding.