Welding Nut Guide for Battery Module Alignment
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Solution Overview
Problem
The assembly of battery modules in battery packs lacks guidance, leading to dislocation and reduced structural strength, resulting in assembly failures during the manufacturing process.
Innovation Solution
Incorporating a welding nut with an upper end that extends upward and is inserted into bolt fastening grooves on the battery modules, providing a guide for precise positioning and coupling to the base plate, along with a cooling assembly to maintain module temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery modules are mounted on the base plate without guidance structures, then the manufacturing process is simple, but the battery modules become dislocated and assembly reliability deteriorates
Solution Approach 1:
The welding nut includes a guide part that protrudes upward from the nut part to preliminarily guide the battery module into the correct position before fastening. This preliminary guidance action ensures accurate positioning and prevents dislocation during assembly, thereby improving assembly reliability without requiring complex external guidance structures.
Solution Approach 2:
The guide part of the welding nut acts as an intermediary element between the battery module and the base plate. It mediates the positioning process by providing a protruding structure that fits into a corresponding groove on the battery module, ensuring accurate alignment and preventing dislocation during assembly.
2Manufacturing precision
If battery modules are mounted without positioning guidance, then the manufacturing process is fast, but manufacturing precision deteriorates due to dislocation
Solution Approach 1:
The guide part protruding from the welding nut performs preliminary positioning action before the fastening process. The guide part fits into the groove on the battery module to pre-align the module with the base plate, ensuring manufacturing precision is achieved without requiring additional positioning steps that would slow down assembly.
Solution Approach 2:
The guidance function and fastening function are merged into a single welding nut component. The guide part and nut part form an integrated structure that simultaneously provides positioning guidance and secure fastening, eliminating the need for separate guidance components and maintaining assembly speed while improving positioning precision.
3Reliability
If the welding nut has an extended upper end inserted into the bolt fastening groove, then assembly reliability is improved, but device complexity increases
Solution Approach 1:
The welding nut is designed with multi-functionality: the guide part provides positioning guidance while the nut part provides fastening. This single component performs both guidance and fastening functions, improving mounting reliability without requiring additional separate components, thus limiting the increase in overall device complexity.
Solution Approach 2:
The guide part of the welding nut performs preliminary positioning action by fitting into the bolt fastening groove before the fastening process. This preliminary action ensures accurate positioning and improves mounting reliability, while the integrated design keeps the added complexity minimal.
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 accurate alignment and secure mounting of battery modules, enhancing the structural integrity and manufacturing efficiency of battery packs by preventing dislocation and improving assembly reliability.
Implementation Method 1
a cooling assembly that is disposed between the base plate and bottom portions of the battery modules, and through which a refrigerant flows so as to cool the battery modules
Data Source
AI summary
A battery pack that includes a plurality of battery modules arranged adjacent to each other and mounted on a base plate, the base plate including a module receiving part on which the battery modules are mounted, and a cooling assembly that is disposed between the base plate and bottom portions of the battery modules and through which a refrigerant flows so as to cool the battery modules. In order to couple the battery modules to the base plate, bolt fastening grooves are drilled in the height direction of the battery module at respective corners on the horizontal surface of the battery module, and welding nuts are inserted through openings and fitted to the base plate at positions corresponding to the bolt fastening grooves.