Design And Development Of Assembly Tool For Power Battery Cover

Power battery,an important building block of the new energy vehicle,is crucial to the performance of the vehicle.As its carrier,the battery box plays a role of safety protection.It mainly consists of the box cover,insulation board,lower box body and lifting eye.The cover and the lower box body are connected by bolts.In order to ensure a reliable connection,the bushing is necessary to be pressed into the connecting hole of the cover.With the large all-in-one power battery box cover jointly produced by a science and technology company in Hangzhou and SAIC New Energy Company as the research object,this paper designed and developed an assembly tooling for power battery box cover,and conducted a study on the following aspects.1.According to the design requirement of the tooling equipment and the analysis and research for the structural features of the power battery box cover,the main components of the tooling equipment were determined,thereby obtaining the overall design scheme.2.The modal analysis for the power battery box cover was conducted due to a high incidence of cracks in the process of manual assembly.In the establishment of finite element model,because the model was oversized and damaged,half of the models were meshed based on the symmetrical characteristics of the model,with the modal calculation conducted,and the results evaluated.The results showed that power battery box cover met the design requirements,eliminating the factors causing the assembly cracks because of the structural problems of the power battery box itself.3.Pressure assembling force is the main parameter of the tooling equipment.Considering the complexity of bushing pressing process,the pressure assembling force was calculated by theoretical method and finite element simulation,with the theoretical value and the simulation value nearly the same.4.Based on the overall design scheme of the assembly tooling,the clamping scheme,press fitting mechanism,bench,pneumatic circuit and control system were designed,and the prototype of the equipment was manufactured and put into actual production.The test results showed that the tooling equipment can cut the production cost,improve the production efficiency and meet the design requirements.