Storage Cell Lug Folding Mechanism for Reliable Electrode Contacting
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Solution Overview
Problem
Existing methods for producing storage cells for electrical energy storage devices, particularly in motor vehicles, are inefficient, costly, and lack process reliability, especially in the folding and connection of electrode foils and contacting lugs.
Innovation Solution
A method and processing device utilizing a rotatable base with pivoting processing elements and guides to fold and connect electrode foils and contacting lugs efficiently and reliably, using a base rotation and gear mechanism to facilitate simultaneous and precise folding of contacting lugs onto a contact element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual handling and folding of electrode foils and contacting lugs is used, then flexibility and adaptability are maintained, but production time increases and process reliability decreases
Solution Approach 1:
The processing device is divided into multiple processing elements (first processing element, second processing element, etc.), each responsible for specific folding operations on different contacting lugs. This segmentation allows parallel processing of multiple lugs simultaneously, significantly reducing production time while maintaining organized and manageable device complexity
Solution Approach 2:
The processing elements are designed to be movable relative to the base, with each element capable of independent pivoting motion. This dynamic configuration allows the device to adapt to different electrode foil sizes and shapes while enabling simultaneous folding operations, improving productivity without requiring an overly complex fixed structure
2Reliability
If conventional folding methods are used, then device complexity is minimized, but contamination risk increases and connection reliability decreases
Solution Approach 1:
The processing elements are designed to automatically fold the contacting lugs onto the contact element through their pivoting motion, without requiring manual intervention. This self-service mechanism eliminates contamination risks from manual handling and ensures consistent, reliable folding and connection processes
Solution Approach 2:
The processing elements are positioned and configured in advance to perform the folding operation in a predetermined sequence. The first processing element folds contacting lugs in a first direction, and the second processing element folds them in a second direction, ensuring proper alignment and connection before final assembly
3Productivity
If simultaneous folding of contacting lugs is implemented, then productivity increases, but device complexity and control difficulty increase
Solution Approach 1:
The processing device uses multiple independent processing elements instead of a single complex mechanism. Each processing element handles specific contacting lugs independently, allowing simultaneous folding operations while keeping each individual element simple and easy to control
Solution Approach 2:
Each processing element is designed with multi-functionality, capable of folding contacting lugs in different directions and accommodating different electrode foil configurations. This universality allows the device to perform multiple folding operations simultaneously using standardized components, reducing overall device complexity
Data Source
AI summary
A method for producing a storage cell for an electrical energy storage device includes providing an electrode winding having an electrode foil. A processing device is provided, having a base, which is rotatable about a base axis of rotation, and processing elements, which are each rotatable about an element axis of rotation relative to the base and which engage with a particular arcuate guide, assigned to the particular processing element, of the base. The base is rotated relative to the electrode winding, relative to the element axes of rotation and relative to the processing elements about the base axis of rotation, whereby the guides cause the processing elements to perform a particular pivoting movement about the element axes of rotation relative to the electrode winding, relative to the base and toward the base axis of rotation.