Parallel Battery Module Welding Layout for Continuous Operation
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Solution Overview
Problem
The existing welding systems for battery module assemblies in electric vehicles are costly to establish and require frequent shutdowns due to the need for multiple specialized welding facilities, which hampers efficiency and operation rates.
Innovation Solution
A welding system comprising a main conveyor, parallel auxiliary conveyors, a loading-unloading module, clamping jigs, and multiple welding robots, allowing for parallel processing and redundancy to maintain operation even if one conveyor or robot is abnormal, with a controller managing the process to optimize efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple specialized welding facilities are installed along the conveyor, then welding capability is improved, but system cost and complexity increase
Solution Approach 1:
The patent employs multiple auxiliary conveyors that can perform welding operations at different positions, allowing a single conveyor system to serve multiple welding functions. This multi-functional approach enables the system to perform various welding operations without requiring separate specialized facilities for each welding point, thereby reducing overall system complexity while maintaining versatile welding capability.
Solution Approach 2:
The welding system is divided into multiple independent auxiliary conveyors, each capable of performing welding operations. This segmentation allows the system to distribute welding tasks across multiple modular units rather than requiring one large complex facility, making the system more manageable and easier to maintain while providing comprehensive welding coverage.
2Adaptability or versatility
If welding facilities are disposed in series along the conveyor, then complete welding coverage is achieved, but production efficiency decreases due to sequential processing
Solution Approach 1:
The patent transitions from a one-dimensional sequential arrangement of welding facilities to a two-dimensional parallel configuration with multiple auxiliary conveyors operating simultaneously. This dimensional change enables multiple welding operations to occur at the same time rather than in sequence, significantly improving production efficiency while maintaining comprehensive welding coverage across all battery module assemblies.
Solution Approach 2:
By implementing parallel auxiliary conveyors that can operate simultaneously, the system ensures continuous welding operations without idle time between sequential processes. Multiple conveyors work in parallel to maintain constant production flow, eliminating the downtime that would occur if one facility needed maintenance or adjustment, thereby sustaining continuous useful action throughout the welding process.
3Adaptability or versatility
If welding facilities are arranged in series, then all welding points are covered, but operation rate decreases when one facility is broken or needs cleaning
Solution Approach 1:
The patent incorporates redundant auxiliary conveyors that serve as backup capacity before failures occur. When one auxiliary conveyor is broken or requires cleaning, the system can immediately redirect work to the remaining operational conveyors, cushioning against production disruptions. This beforehand cushioning through redundancy ensures operation continuity and maintains reliability even when individual facilities experience failures.
Solution Approach 2:
The system can dynamically change operational parameters by activating or deactivating specific auxiliary conveyors based on their operational status. When one conveyor is unavailable, the system adjusts by modifying the workload distribution among remaining conveyors, changing operational parameters to maintain overall welding coverage and ensure continuous production without interruption.
4Manufacturing precision
If multiple specialized welding facilities are installed, then welding precision is improved, but establishment cost increases significantly
Solution Approach 1:
The patent uses multiple auxiliary conveyors that replicate the welding functionality across parallel lines rather than requiring one highly complex specialized facility for each welding point. Each auxiliary conveyor is a standardized copy that can perform welding operations, reducing the need for expensive custom-built specialized equipment while maintaining welding precision through consistent replication of proven welding capabilities across multiple units.
Data Source
AI summary
Disclosed are a welding system and a welding method using the same. The welding system may include: a main conveyor configured to convey a battery palette on which a battery module assembly is mounted; at least two auxiliary conveyors disposed in parallel with the main conveyor; a loading-unloading module configured to transfer the battery palette, which is conveyed along the main conveyor, to the auxiliary conveyor and transfer the battery palette, which is completely subjected to a preset welding process, from the auxiliary conveyor to the main conveyor; clamping jigs on which the battery palettes are seated by the loading-unloading module so that the preset welding process is performed on the battery module assemblies on the auxiliary conveyors; and at least two welding robots configured to weld the battery module assemblies seated on the at least two auxiliary conveyors.