Battery lift and transfer solutions for assembling traction battery packs
Manufacturing processes are disclosed for assembling traction battery packs that battery systems. Exemplary traction battery pack assembly methods may include lifting and transferring battery cells between assembly line workstations, such as a cell matrix assembly workstation and a welding workstation. The method may further involve the use of automated tooling, such as a cell-to-matrix pusher and a cell matrix support structure that includes locator pads for supporting a non-rigid grouping of battery cell during workstation transfers.
1 . A method of assembling a traction battery pack using an assembly line, the method comprising:
inserting a cell matrix into a cell-receiving opening of a halo structure of a halo pallet at a first workstation of the assembly line;
lifting the halo pallet with a cell matrix support structure that is at least partially positioned beneath the halo pallet;
transferring the halo pallet from the first workstation to a second workstation of the assembly line with the cell matrix support structure; and
positioning the halo pallet on top of a weld pallet located at the second workstation.
2 . The method as recited in claim 1 , wherein the cell matrix is a subcomponent of a cell-to-pack battery system of the traction battery pack.
3 . The method as recited in claim 1 , wherein the first workstation is a cell matrix assembly workstation and the second workstation is a welding workstation.
4 . The method as recited in claim 1 , wherein inserting the cell matrix includes pushing the cell matrix upwardly into the cell-receiving opening of the halo structure with a plunger of a cell-to-matrix pusher assembly.
5 . The method as recited in claim 4 , comprising backing the plunger away from the halo pallet prior to lifting the halo pallet.
6 . The method as recited in claim 1 , comprising positioning a locator pad of the cell matrix support structure within a gap located between an adjacent pair of plungers of a cell-to-matrix plunger assembly prior to lifting the halo pallet.
7 . The method as recited in claim 6 , comprising backing the plungers away from the halo pallet after positioning the locator pad within the gap.
8 . The method as recited in claim 1 , wherein positioning the halo pallet on top of the weld pallet includes positioning a locator pad of the cell matrix support structure within a gap located between an adjacent pair of pusher blocks of the weld pallet.
9 . The method as recited in claim 1 , comprising, during the lifting and the transferring, supporting the cell matrix from a location beneath the cell matrix with the cell matrix support structure.
10 . The method as recited in claim 9 , wherein supporting the cell matrix includes supporting a first cell stack of the cell matrix with a first locator pad of the cell matrix support structure.
11 . The method as recited in claim 10 , wherein supporting the cell matrix includes supporting a second cell stack of the cell matrix with a second locator pad of the cell matrix support structure.
12 . A method of assembling a traction battery pack using an assembly line, the method comprising:
inserting a cell matrix into a cell-receiving opening of a halo structure of a halo pallet at a first workstation of the assembly line;
lifting the halo pallet with a cell matrix support structure that is at least partially positioned beneath the halo pallet;
transferring the halo pallet from the first workstation to a second workstation of the assembly line with the cell matrix support structure;
positioning the halo pallet on top of a weld pallet located at the second workstation; and
welding a busbar module to the cell matrix at the second workstation.
13 . The method as recited in claim 12 , wherein the welding includes laser welding.
14 . A method of assembling a traction battery pack using an assembly line, the method comprising:
inserting a cell matrix into a cell-receiving opening of a halo structure of a halo pallet at a first workstation of the assembly line;
lifting the halo pallet with a cell matrix support structure that is at least partially positioned beneath the halo pallet;
transferring the halo pallet from the first workstation to a second workstation of the assembly line with the cell matrix support structure;
during the lifting and the transferring, supporting the cell matrix from underneath with the cell matrix support structure; and
performing a welding operation on the cell matrix at the second workstation.
15 . The method as recited in claim 14 , wherein the welding operation is a laser welding operation.
16 . The method as recited in claim 14 , wherein performing the welding operation includes welding a busbar module to the cell matrix.
17 . The method as recited in claim 14 , wherein inserting the cell matrix includes pushing the cell matrix upwardly into the cell-receiving opening of the halo structure with a cell-to-matrix pusher assembly.
18 . The method as recited in claim 17 , comprising positioning a locator pad of the cell matrix support structure within a gap located between an adjacent pair of plungers of a cell-to-matrix plunger assembly prior to lifting the halo pallet.
19 . The method as recited in claim 14 , wherein transferring the halo pallet includes positioning a locator pad of the cell matrix support structure within a gap located between an adjacent pair of pusher blocks of a weld pallet of the second workstation.
20 . The method as recited in claim 14 , comprising, prior to inserting the cell matrix, using a locator pin to locate the halo structure relative to the halo pallet.