Segmented Box Beam Structure for Faster Battery Pack Manufacturing
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Solution Overview
Problem
The manufacturing of box beams is costly and time-consuming due to the need for specialized rolling dies, which are expensive and have long development cycles, and the process of bending a whole plate to form a box beam with a closed opening is difficult and prolongs production time.
Innovation Solution
The box beam is composed of two separate bodies, a first body and a second body, which are processed separately and then connected to close openings, allowing for efficient bending and assembly without the need for expensive rolling dies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a whole plate is used to manufacture the box beam through multiple bending operations, then the box beam structure is formed, but the manufacturing period is prolonged and production efficiency is reduced
Solution Approach 1:
The box beam is divided into two separate bodies, each with an opening, that are processed independently and then connected. This segmentation allows parallel processing of multiple components instead of sequentially bending a single whole plate through multiple operations, significantly reducing the manufacturing period while maintaining the complete box beam structure.
2Shape
If a specialized rolling die is used to manufacture the box beam, then the box beam can be formed, but the production line cost increases and development period is extended
Solution Approach 1:
By segmenting the box beam into two bodies that can be processed separately, the invention eliminates the need for complex specialized rolling dies. Standard bending equipment can be used to process each body independently, reducing both the initial production line cost and the development period for new box beam designs.
Solution Approach 2:
Instead of forming a closed box beam structure through multiple bending operations on a whole plate using expensive rolling dies, the invention inverts the approach by creating two open bodies that are connected afterward. This reversal of the manufacturing sequence simplifies the forming process and reduces equipment requirements.
3Shape
If multiple bending operations are performed on a whole plate to form a closed opening box beam, then the box beam is manufactured, but the process complexity increases and production efficiency decreases
Solution Approach 1:
The manufacturing process is segmented into two independent body fabrications followed by a connection operation. Each body requires fewer bending operations compared to forming a complete closed structure from a whole plate, reducing the overall process complexity while achieving the same closed opening structure.
Solution Approach 2:
The two bodies are prepared in advance with their respective openings before being connected. This preliminary preparation allows each component to be optimized and processed independently, simplifying the overall manufacturing process compared to performing multiple sequential bending operations to achieve the closed structure in one piece.
Data Source
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AI summary
A box beam, a battery-pack box, and a battery pack are provided in the present application, to improve problems that the manufacturing period of the box beam is long due to the whole plate structure of the box beam. The box beam includes a first body and a second body. The second body is provided separately from the first body. At least one of a section of the first body and a section of the second body is provided with an opening. The first body and the second body are connected on two sides of the opening, and close the opening.