Terminal Locating Feature for Battery Assembly Alignment
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Solution Overview
Problem
In electrified vehicle battery assemblies, existing methods face challenges in reliably connecting bus bars to terminals due to misalignment issues, which can lead to inconsistent welds and defects.
Innovation Solution
The use of a locating feature within terminal holders that engage with adjacent holders to position terminals vertically and horizontally, ensuring precise alignment for welding bus bars to terminals, and a method involving extensions and apertures to secure the bus bar module through laser welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If terminal holders are connected without locating features, then assembly process is simpler, but terminal alignment precision deteriorates leading to inconsistent welds
Solution Approach 1:
The locating feature acts as an intermediary element between terminal holders, providing a dedicated alignment mechanism. The extension on one terminal holder fits into the aperture of the adjacent terminal holder, serving as a mechanical mediator that ensures precise positioning without requiring complex external fixtures or adjustment mechanisms.
Solution Approach 2:
The patent replaces complex mechanical alignment systems with a simple geometric interlocking mechanism. Instead of using adjustable fixtures, clamps, or multiple fastening points, the invention uses a straightforward extension-aperture interface that automatically provides alignment when terminal holders are assembled, eliminating the need for elaborate mechanical alignment systems.
2Reliability
If manual alignment methods are used, then device complexity is lower, but welding consistency deteriorates due to misalignment
Solution Approach 1:
The locating feature performs preliminary alignment action during the assembly process itself. As terminal holders are brought together for welding, the extension automatically engages with the aperture, pre-positioning the terminals in correct alignment before the welding operation begins. This eliminates the need for separate alignment steps or manual adjustment procedures.
Solution Approach 2:
The terminal holders self-align through the locating feature mechanism. The extension and aperture configuration enables the assembly to automatically correct its own positioning errors, with the geometry of the locating features guiding the terminal holders into proper alignment without external intervention or complex positioning systems.
3Measurement precision
If locating features are added to terminal holders, then terminal positioning is improved, but manufacturing complexity increases
Solution Approach 1:
The locating feature applies the principle of local quality by concentrating the alignment function in a specific localized region of the terminal holder. Rather than requiring precision throughout the entire component, only the extension and aperture regions need precise geometric control, while other portions of the terminal holder can be manufactured with standard tolerances, simplifying the overall manufacturing process.
Solution Approach 2:
The locating feature utilizes asymmetric geometry where the extension on one terminal holder complements the aperture on the adjacent holder. This asymmetric interlocking design provides unique alignment in specific directions (vertical and horizontal positioning) while maintaining manufacturing simplicity, as the asymmetric features can be integrated into standard molding or fabrication processes.
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 reliable electrical connection of battery cells by eliminating misalignment issues, resulting in consistent welds and improved assembly quality, reducing defects and enhancing the overall performance of the battery assembly.
Implementation Method 1
The first terminal holder includes a locating feature to position the first terminal holder relative to a second terminal holder
Implementation Method 2
Bus bars may be used to electrically connect the battery cells of a battery assembly
Implementation Method 3
the welding comprises laser welding
Data Source
AI summary
An exemplary battery assembly includes a first terminal holder, and a terminal at least partially surrounded by the first terminal holder. The first terminal holder includes a locating feature to position the first terminal holder relative to a second terminal holder.