Battery Pack Terminal Clamp for Reliable Busbar Welding
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Solution Overview
Problem
Existing methods for assembling traction battery packs face challenges in securely fastening tab terminals to busbars, particularly in ensuring robust and reliable connections.
Innovation Solution
A method involving a clamping fixture that presses tab terminals against busbars, using apertures with tapered openings and elongated slots to facilitate welding, ensuring secure attachment through mechanical fasteners and welding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fastening methods are used for tab terminals to busbars, then the assembly process is simpler, but the connection reliability and robustness are insufficient
Solution Approach 1:
The patent combines mechanical clamping and welding operations into a single integrated clamping fixture. The fixture simultaneously applies clamping force to hold the terminal against the busbar and provides access apertures for welding, merging two separate fastening methods into one unified system that improves reliability without proportionally increasing complexity
Solution Approach 2:
The clamping fixture acts as an intermediary tool that facilitates the connection between tab terminals and busbars. It provides a controlled environment for both mechanical fastening and welding operations, mediating the interaction between components to achieve robust connections while managing the complexity through a dedicated auxiliary device
2Strength
If welding is performed without proper access, then the assembly process is faster, but the welding quality and connection strength are compromised
Solution Approach 1:
The clamping fixture incorporates localized apertures at specific positions where welding access is required. Rather than making the entire fixture complex, only the necessary access points are provided, allowing welding operations to be performed with proper access while maintaining simplicity in other areas of the fixture design
Solution Approach 2:
The fixture design segments the clamping and welding functions into distinct but integrated components. The clamping mechanism and welding access apertures are separate functional elements within the same fixture, allowing each to be optimized independently while working together to achieve strong welds without excessive overall complexity
3Manufacturing precision
If clamping force is not applied during welding, then the process is simpler, but the terminal may shift causing poor connection
Solution Approach 1:
The clamping fixture applies preliminary clamping force to secure the tab terminal against the busbar before the welding operation begins. This preliminary positioning ensures the terminal remains precisely in place during welding, achieving high manufacturing precision without requiring complex real-time adjustment mechanisms during the welding process itself
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
The method provides a robust and reliable connection between tab terminals and busbars, enhancing the assembly process by ensuring positive clamping force and efficient welding access.
Implementation Method 1
pressing the at least one terminal against the busbar using a clamping fixture
Implementation Method 2
securing the at least one terminal to the busbar by welding the at least one terminal to the busbar
Implementation Method 3
the welding is laser welding
Data Source
AI summary
A method of assembling a battery pack includes inserting at least one terminal through a slot of a cross-member assembly, folding the at least one terminal over a busbar of the cross-member assembly, pressing the at least one terminal against the busbar using a clamping fixture, and securing the at least one terminal to the busbar through at least one aperture in the clamping fixture.