Spring-Loaded Clamping Plates for Reliable Battery Tab Welding
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Solution Overview
Problem
In vehicle traction battery manufacturing, there is a challenge in ensuring repeatable and robust electrical connections between busbar assemblies and cell terminals, as faulty connections can lead to module malfunction and require reworking or scrapping.
Innovation Solution
A clamping apparatus with spring-loaded clamping elements is used in a laser welding system to apply compressive force to connection tabs of a busbar assembly, ensuring proper alignment and contact with cell terminals during welding, utilizing a support part with gas channels for inert gas supply and allowing laser light passage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a clamping apparatus applies compressive force to connection tabs during laser welding, then the reliability of electrical connections is improved, but the device complexity increases
Solution Approach 1:
The clamping apparatus is divided into multiple independent clamping elements, each capable of applying compressive force to individual connection tabs. This segmentation allows the system to maintain reliability across multiple connection points while keeping each individual clamping element relatively simple in structure.
Solution Approach 2:
The clamping elements serve multiple functions: they apply compressive force during welding, maintain alignment between connection tabs and terminals, and provide structural support during the welding process. This multi-functionality reduces the need for separate devices for each function, thereby managing overall device complexity.
2Speed
If clamping elements have a low profile design, then laser access is improved, but the compressive force application capability is reduced
Solution Approach 1:
The clamping elements feature a curved or tapered profile rather than a flat design. This curvature allows the laser beam to access the welding location more effectively while the gradual taper maintains sufficient compressive force application capability throughout the reduced profile height.
Solution Approach 2:
The clamping elements are designed with optimized three-dimensional geometry, transitioning from a simple flat profile to a more complex curved shape that accommodates both laser access requirements and force application needs in multiple spatial dimensions.
3Adaptability or versatility
If the clamping apparatus accommodates terminal variations, then the adaptability is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The clamping elements are designed with dynamic characteristics that allow them to adjust to varying terminal positions and orientations. This adaptability is achieved through the geometric design that can accommodate variations while maintaining consistent clamping force, managing the precision requirements through flexible geometry rather than rigid tolerances.
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 ensures secure and consistent welding of busbar connections to cell terminals, reducing the risk of faulty connections and improving manufacturing efficiency by accommodating terminal variations and maintaining a low profile for efficient laser access.
Implementation Method 1
provide compressive force to a plurality of connection tabs of a busbar assembly and press each connection tab onto a corresponding terminal
Implementation Method 2
a central space configured to allow the passage of laser light therethrough to perform the laser welding
Implementation Method 3
an opening through the peripheral outer wall, the opening configured to allow a flow of gas between the central space and outside the clamping element
Data Source
AI summary
A clamping apparatus for use in a laser welding system comprises a support part having a clamping face, and clamping elements extending from the clamping face. The clamping apparatus comprises spring elements that are each mounted on a respective spring element. Each of the clamping elements is arranged to provide a compressive force to a respective connection tab of a busbar assembly when a compressive force is applied to the support part, to press each respective connection tab onto a corresponding terminal of an electrical cell of a cell array. Each spring element is configured to compress when the compressive force is applied to the support part and when the corresponding clamping element mounted on the spring element contacts the respective connection tab to be laser welded.