Automated Thermal Battery Manufacturing with Laser Welding
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Solution Overview
Problem
Manual manufacturing of thermal batteries is prone to human error, variability, and inefficiency, leading to suboptimal performance and increased production time, with a need for improved automation and testing methods.
Innovation Solution
An automated system comprising a press system, stacking system, and enclosing system that forms, sorts, and hermetically seals thermal battery pellets, utilizing a positive air pressure pellet carrier and laser welding to ensure consistent pellet formation and assembly, and an inventory system for tracking and retrieval of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual manufacturing techniques are used, then flexibility and adaptability are maintained, but human error and variability increase, reducing manufacturing precision and reliability
Solution Approach 1:
The patent replaces manual mechanical operations with automated systems. Specifically, an automated press system with servo control replaces manual pressing operations to form pellets with consistent density and dimensions. The automated stacking system replaces manual assembly, using robotic or automated mechanisms to position pellets and components with precise control, thereby eliminating human error and variability while maintaining high manufacturing precision.
Solution Approach 2:
The automated system incorporates self-regulating mechanisms that monitor and adjust parameters during manufacturing. The press system automatically controls pressure and timing, while the stacking system self-adjusts positioning based on sensor feedback, reducing reliance on manual intervention and ensuring consistent pellet formation and assembly without human error.
2Productivity
If manual processing is used, then device complexity is reduced, but production time increases and productivity decreases
Solution Approach 1:
The manufacturing system is divided into distinct modular segments: a press system for pellet formation, a stacking system for assembly, and an enclosing system for sealing. Each module operates independently but coordinates through standardized interfaces, allowing parallel processing and reducing overall production time while keeping individual module complexity manageable.
Solution Approach 2:
The press system pre-forms pellets with controlled density and dimensions before stacking, and the stacking system pre-positiones components during assembly. This preliminary preparation eliminates the need for time-consuming adjustments during final assembly, significantly increasing production speed while the modular architecture prevents excessive system complexity.
3Reliability
If manual assembly is used, then ease of operation is maintained, but hermetic sealing quality and reliability decrease
Solution Approach 1:
The enclosing system replaces manual sealing operations with automated laser welding or hermetic sealing mechanisms. These automated systems provide consistent, repeatable sealing quality that exceeds manual capability, ensuring high hermeticity test pass rates. The automation handles the complexity of precise positioning and controlled sealing parameters, making the operation simple to initiate while maintaining high reliability.
Solution Approach 2:
The hermetic sealing process incorporates sensors and feedback mechanisms that monitor sealing quality in real-time. The system automatically adjusts parameters such as pressure, temperature, or welding current based on sensor feedback, ensuring consistent seal quality and high reliability while the automated control interface maintains operational simplicity for the operator.
4Manufacturing precision
If automated systems are implemented, then manufacturing precision and consistency improve, but initial system complexity and investment increase
Solution Approach 1:
The automated manufacturing system is segmented into three independent but coordinated modules: press system, stacking system, and enclosing system. Each module can be developed, tested, and maintained separately, reducing the complexity burden on any single component while achieving high overall assembly consistency through their coordinated operation.
Solution Approach 2:
The automated press and stacking systems are designed with universal capabilities that can handle multiple pellet types and configurations through programmable control. This multi-functionality reduces the need for dedicated equipment for each product variant, managing system complexity while maintaining high manufacturing precision across different thermal battery designs.
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 automated system enhances the consistency and quality of thermal battery production, reduces production time, and increases efficiency, while improving the chances of passing hermeticity tests, resulting in higher-quality batteries with reduced manual errors.
Implementation Method 1
the press system and stacking system utilize a positive air pressure pellet carrier device configured to use the Bernoulli principle to lift and transport pellets
Implementation Method 2
the enclosing system is configured to laser weld a seam between a thermal battery container (e.g., a metal cylinder or 'can') and a thermal battery cap
Data Source
AI summary
An automated system and method for manufacturing a thermal battery is disclosed. In an exemplary embodiment, the system comprises a press system, a stacking system, and an enclosing system to automate the manufacturing process of thermal batteries. A method of manufacturing a thermal battery using the system is also disclosed. An automated tracking, storage, and retrieval system for pellets used in the manufacturing process and a pellet pairing system are also disclosed.