Claims:
CLAIMS:

1. A battery module manufacturing system (1000), comprising:
an electrode head (1100), further comprising:
electrodes (1110) & (1110), having opposite electrical polarity, for welding at least a conductor (1200) to at least one battery cell (1510), wherein each electrode (1110) is further coupled to one or more electrode tips (1120),
a welding axis (1810), wherein the welding axis (1810) is an imaginary line normal to the surface of the battery cell (1510) on which resistance welding has to be performed,
a compression mechanism (1300), comprising a spring (1310) for each electrode (1110), a spring shaft (1320) for each spring (1310), at least one guide rod (1350) for each spring (1310), a preloader (1341) for each spring shaft (1320), a preloader lock (1342) for each preloader (1341), wherein the compressive force for welding is generated by motion of one or more electrode heads (1100) along the welding axis (1810) and by virtue of spring stiffness (1330) and set preload (1340);
a head platform (1610), coupled to the electrode head (1100), further coupled to a ball screw assembly (1410), and a linear guide assembly (1420), wherein the head platform (1610) translates along the welding axis (1810) by an electrical motor (1750) which is coupled to the ball screw assembly (1410) with a coupler (1430);
a lateral axis (1820), aligned at a predefined angle alpha (1910) with respect to the welding axis (1810);
a longitudinal axis (1830), aligned at a predefined angle beta (1920) with respect to the welding axis (1810), wherein the longitudinal axis (1830) is further aligned at a predefined angle gamma (1930) with respect to the lateral axis (1820) such that the welding axis (1810), the lateral axis (1820) and the longitudinal axis (1830) form a coordinate system for the described battery module manufacturing system (1000);
a lateral platform (1620), coupled to the head platform (1610) through the said ball screw assembly (1410) and the said linear guide assembly (1420), further coupled to another ball screw assembly (1411) and another linear guide assembly (1421), wherein the lateral platform (1620) translates along the lateral axis (1820) by an electrical motor (1751) which is coupled to the ball screw assembly (1411) with a coupler (1431);
a stand platform (1630), coupled to the lateral platform (1620) through the said ball screw assembly (1411) and said linear guide assembly (1421), wherein the stand platform (1630) is further coupled to a base plate (1632) through one or more stands (1631);
a longitudinal platform (1640), coupled to the base plate (1632) through another ball screw assembly (1412) and another linear guide assembly (1422), wherein the longitudinal platform (1640) translates along the longitudinal axis (1830) by an electrical motor (1752) which is coupled to the ball screw assembly (1412) with a coupler (1432);
at least one primary battery clamp (1650) configured to be attached to the longitudinal platform (1640), wherein the position of said one or more primary battery clamps (1650) is adjustable relative to the longitudinal platform (1640) for fine positional adjustment of battery module (1520);
at least one secondary battery clamp (1651) configured to be attached to the longitudinal platform (1640), wherein the position of said one or more secondary battery clamps (1651) is adjustable relative to the longitudinal platform (1640) for a coarse positional adjustment of the battery module (1520);
at least one module locator (1641) configured to be attached to the longitudinal platform (1640), wherein said one or more module locators (1641) are adjustable with respect to the longitudinal platform (1640) and lock the position of battery module (1520) with the longitudinal platform (1640);
an electronic control unit (1710) electrically coupled with said electrical motors (1750), (1751) and (1752), wherein the electronic control unit (1710) is powered by a power unit (1730) and operates the electrical motors (1750), (1751) and (1752) to obtain desired tool path (1780) for the welding of one or more battery cells (1510) with the electrical conductors (1120); and
an energy storage unit (1720) electrically coupled to the electrodes (1110) & (1110), the energy storage unit (1720) further comprises one or more capacitors (1722) and one or more transistors (1721), wherein the energy storage unit (1720) is powered by the power unit (1730) and the welding current is generated by the discharge of said on or more capacitors (1722) through said one or more transistors (1721), wherein the transistors (1721) are operated by the electronic control unit (1710);

wherein, the electrode head (1100) coupled to the energy storage unit (1720) applies desired compressive force on the conductors (1200) generated from the compression mechanism (1300), furthermore, the electrode head (1100) provides electrical energy to the conductors (1200) obtained from the energy storage unit (1720) as commanded by the electronic control unit (1710) which is then converted to heat energy by virtue of resistance of conductors (1200), thus resistively welding the conductors (1200) on the battery cells (1510) in an automated manner.

2. The battery module manufacturing system (1000) as claimed in Claim 1, wherein the spacing between one or more electrode tips (1120) from the said one or more battery cells (1510) is adjustable.

3. The battery module manufacturing system (1000) as claimed in Claim 1, wherein the welding axis (1810), lateral axis (1820), and longitudinal axis (1830) are mutually perpendicular.

4. The battery module manufacturing system (1000) as claimed in Claim 1, wherein the electrode (1110) and one or more electrode tips (1120) are either a single unit or multiple units.

5. The battery module manufacturing system (1000) as claimed in Claim 1, wherein the stand platform(1630) and one or more stands (1631) are either a single unit or multiple units.

6. The battery module manufacturing system (1000) as claimed in Claim 1, wherein the longitudinal platform (1640), the one or more primary battery clamps (1650), the one or more secondary battery clamps (1651), one or more module locators (1641) are manufactured from an electrically insulated material.

7. The battery module manufacturing system (1000) as claimed in Claim 1, wherein the electronic control unit (1710) is operatively coupled to one or more rotary encoders (17340) mounted suitably with the electrical motors (1750), (1751) , (1752), to form a closed loop operation.

8. The battery module manufacturing system (1000) as claimed in Claim 1, wherein the energy storage unit (2000) is electrically coupled to the electrodes (1110) via a relay (2010) or switch (2011), wherein the relay (2010) or switch (2011) is manually operated to enable or disable welding operation.

9. The battery module manufacturing system (1000) as claimed in Claim 1, wherein the electronic control unit (1710) is further operatively coupled to one or more limit sensors (1760) to avoid any undesired motion of the head platform (1610), the lateral platform (1620) or the longitudinal platform (1640).

10. The battery module manufacturing system (1000) as claimed in Claim 1, wherein the electrode head (1100) further comprises an alignment assembly (1130), wherein the alignment assembly (1130) comprises a laser light (1131),
wherein, the alignment assembly (1130) provides relative alignment of the battery module (1520) with the one or more electrode heads (1100);

11. The alignment assembly (1130) as claimed in Claim 2, wherein the laser light (1131) is either of cross or spot type.

12. A method for manufacturing a battery module (5000), using battery module manufacturing system (1000) as claimed in Claim 1, comprising the following processes:
programming the electronic control unit (1710) to generate a desired tool path (1780) and desired welding parameters (1781);
assembling the battery cells (1510) in the support structure (1520) to form a battery module (1570);
locating the assembled battery module (1570) on the longitudinal platform (1640) using one or more primary battery clamps (1650), secondary battery clamps (1651) & module locators (1641);
resistance welding of conductors (1200) on the battery cells (1510) in the assembled battery module (1570) using generated tool path (1780) and welding parameters (1781), thereafter removing the manufactured battery module (1570) from battery module manufacturing system (1000);
wherein, the program of the electronic control unit (1710) remains same if the next battery module (1570) to be resistance welded is identical to the manufactured battery module (1570) and the program of the electronic control unit (1710) is changed if the next battery module (1570) to be resistance welded is different from the manufactured battery module (1570);

13. A method for manufacturing multiple battery modules (6000) simultaneously using battery module manufacturing system (1000) as claimed in Claim 1 comprising the following processes:
programming the electronic control unit (1710) to generate a desired tool path (1780) and desired welding parameters (1781);
locating the pre-assembled battery modules (1570) on the longitudinal platform (1640) using one or more primary battery clamps (1650), secondary battery clamps (1651) & module locators (1641);
simultaneously resistance welding of conductors (1200) on the battery cells (1510) in the pre-assembled battery modules (1570) using generated tool path (1780) and welding parameters (1781), thereafter removing the manufactured battery modules (1570) from battery module manufacturing system (1000);
wherein, the manufactured battery modules (1570) are replaced by new pre-assembled battery modules (1570) such that the process of manufacturing is continuous.
, Description:FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(See section 10, rule 13)

“BATTERY MODULE MANUFACTURING SYSTEM
USING AUTOMATED RESISTANCE WELDING”
By
Emflux Motors Pvt. Ltd.
An Indian Company
No. 16, Bhuvanappa Layout, Tavarekere Main Road, Kaveri Layout, Suddagunte Palya, Bengaluru, Karnataka 560029

The following specification particularly describes the invention and the manner in which it is to be performed.

FIELD OF INVENTION

[001] The present invention relates generally to the field of manufacturing battery modules and specifically to a system for automated resistance welding of conductors in a battery module.

BACKGROUND

[002] Battery Modules are widely used for energy storage in applications like electric vehicles, power tools, communication devices, mobile computers, etc. A battery module is an assembly comprising multiple rechargeable battery cells, interconnected electrically, to meet the power and voltage requirements in the application.

[003] A typical rechargeable cylindrical battery cell has a cylindrical outer case formed of conductive metal. This case forms the base of the cell as well as the side wall. The case also serves as the negative terminal or the ground terminal, for the cell. A disk-like piece of metal serves as both the head of the cell and the positive terminal. An insulating ring separates the case from the head to prevent these components from shorting out.

[004] A set of battery cells may be arranged in parallel by sandwiching the cells between two conductors to obtain a desired current. Many of the parallel sets may be coupled in series to obtain a desired voltage of the larger set. The larger set may be electrically coupled in series or parallel with other similarly sized sets to obtain an even higher voltage or power. Batteries can be stacked and coupled in series or parallel to produce higher voltage.

[005] Various manual methods involving resistance welding of conductor with the battery cells have been incorporated for securing electrical interconnections between battery cells. Such methods are time-consuming and hence not well-suited for large scale production. Moreover, manual work may lead to irregular and nonuniform welds, resulting in cell to cell voltage imbalance while discharging.

[006] The present invention discloses a reliable and automated method of electrically interconnecting battery cells in a battery module systems.

SUMMARY

[007] This summary is provided to introduce a selection of concepts in a simple manner that is further described in the detailed description of the disclosure. This summary is not intended to identify key or essential inventive concepts of the subject matter nor is it intended for determining the scope of the disclosure.

[008] In the first embodiment, a manufacturing system is disclosed. The invention pertains to battery module manufacturing. The system comprises of one or more electrode heads where each electrode head contains electrodes having opposite electrical polarity for the purpose of welding a conductor and a battery cell. The electrodes are further coupled to electrode tips. The electrode head consists of a compression mechanism with springs for electrodes and a spring shaft for each spring. The compressive force for welding is generated by motion of electrode along the welding axis and by virtue of spring stiffness and set preload. The welding axis, the lateral axis and the longitudinal axis form a coordinate system for the battery manufacturing system. The head platform which upholds the electrode head, can translate along the welding axis using an electrical motor. The lateral platform is coupled to the head platform via linear guide and ball screw assembly and can translate along the lateral axis to provide the desired motion of the electrode head in the lateral direction relative to the battery module. The stand platform is coupled to the lateral platform via linear guide and ball screw assembly, wherein the stand platform is further coupled to a base plate through one or more stands to provide support to the overall system. The longitudinal platform on which the battery module is rested upon is coupled to the base plate via linear guide and ball screw assembly. The primary battery clamp is provided for fine positional adjustment of battery module whereas secondary battery clamp for a coarse positional adjustment of battery module. The module locator is provided to lock the battery module with longitudinal platform. An electronic control unit which is powered by the power unit operates the electrical motors to obtain the desired tool path for the welding of one or more battery cells with the electrical conductors. The energy storage unit, also powered by the power unit, comprises of capacitors and transistors to provide the welding current for the resistance welding.

[009] The summary above is illustrative only and is not intended to be in any way limiting. Further aspects, exemplary embodiments, and features will become apparent by reference to the drawings and the following detailed description

BRIEF DESCRIPTION OF DRAWINGS

[0010] Embodiments of the disclosure will now be described, by way of example, with reference to the accompanying drawings, in which:

[0011] FIG 1A is a perspective view of the battery module manufacturing system (1000), in accordance with a first embodiment of the present invention.

[0012] FIG 1B is another perspective view of the battery module manufacturing system (1000), in accordance with the first embodiment of the present invention.

[0013] FIG. 2 is a top view of the battery module (1570) assembled in the battery module manufacturing system (1000), in accordance with the first embodiment of the present invention.

[0014] FIG 3A is a perspective view of the electrode head (1100), in accordance with the first embodiment of the present invention.

[0015] FIG 3B is an exploded view of the electrode head (1100), in accordance with the first embodiment of the present invention.

[0016] FIG. 4 illustrates the coordinate system and resistance welding being performed on the battery cell (1510) with the conductor (1200), in accordance with the first embodiment of the present invention.

[0017] FIG. 5 is a flow chart illustrating a manufacturing process of a single battery module (1570), in accordance with a second embodiment of the present invention.

[0018] FIG. 6 is a flow chart illustrating a manufacturing process of multiple battery modules (1570), in accordance with a third embodiment of the present invention.

[0019] Further, persons skilled in the art to which this disclosure belongs will appreciate that elements in the figures are illustrated for simplicity and may not have necessarily been drawn to scale. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the figures by conventional symbols, and the figures may show only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the figures with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.

DETAILED DESCRIPTION
[0020] For the purpose of promoting an understanding of the principles of the disclosure, reference will now be made to the embodiment illustrated in the figures and specific language will be used to describe them. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Such alterations and further modifications to the disclosure, and such further applications of the principles of the disclosure as described herein being contemplated as would normally occur to one skilled in the art to which the disclosure relates are deemed to be a part of this disclosure.

[0021] It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the disclosure and are not intended to be restrictive thereof.

[0022] The terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such a process or a method. Similarly, one or more devices or subsystems or elements or structures or components preceded by "comprises... a" does not, without more constraints, preclude the existence of other devices, other subsystems, other elements, other structures, other components, additional devices, additional sub-systems, additional elements, additional structures, or additional components. Appearances of the phrase “in an embodiment”, “in another embodiment” and similar language throughout this specification may, but do not necessarily all refer to the same embodiment.

[0023] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. The system, methods, and examples provided herein are illustrative only and not intended to be limiting.

[0024] In the following specification and the claims, reference will be made to a number of terms which shall be defined to have the following meanings. The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise.

[0025] Embodiments of the present disclosure relates to a manufacturing system of battery modules by resistance welding the battery cell with the conductors.

[0026] Embodiments of the present disclosure will be described below in detail with reference to the accompanying figures.

[0027] For exemplary and simplicity purpose, the present disclosure and the corresponding drawings explain a battery module comprising “cylindrical battery cells”. However, it is to be noted that the various embodiments of the present disclosure are applicable for battery cells having different geometries in the battery module. Other types of battery cell geometries include prismatic cell geometry, pouch cell geometry, etc.

[0028] Referring to FIG 1A & FIG 1B, the battery module manufacturing system (1000) comprises an electrode head (1100). The electrode head (1100) houses few essential components required for the resistance welding. The electrode head (1100) is further illustrated in FIG 2A & FIG 2B. The electrode head (1100) is mounted on a head platform (1610). The head platform (1610) is coupled to a linear guide assembly (1420) and a ball screw assembly (1410). As used herein, a “linear guide assembly” comprises a guide block which slides over a guide rail thus ensuring relative linear motion of components attached with the linear guide assembly. A “ball screw assembly” is a mechanical assembly of a nut and a threaded screw which translates rotational motion into linear motion. Other mechanisms known in the art, like a lead screw mechanism, may as well be used instead of the ball screw mechanism. The said linear guide assembly (1420) and the ball screw assembly (1410) are further coupled to a lateral platform (1620). Thus the relative linear motion between the two platforms - head platform (1610) & lateral platform (1620) - is achieved by said linear guide assembly (1420) and ball screw assembly (1410).

[0029] Furthermore, the lateral platform (1620) is coupled to another set of linear guide assembly (1421) and ball screw assembly (1411). These linear guide assembly (1421) and ball screw assembly (1411) are further coupled to a stand platform (1630). Thus the relative linear motion between the two platforms - lateral platform (1620) & stand platform (1630) - is achieved by said linear guide assembly (1421) and ball screw assembly (1411).

[0030] The stand platform (1630) is coupled to stands (1631), which are further coupled to a base plate (1632). Thus, the stand platform (1630), the stands (1631) and the base plate (1632) provide structural integrity to the battery module manufacturing system (1000).

[0031] Furthermore, yet another set of linear guide assembly (1422) and ball screw assembly (1412) are mounted on the base plate (1632). A longitudinal platform (1640) is coupled to the said linear guide assembly (1422) and ball screw assembly (1412). Thus the relative linear motion between the longitudinal platform (1640) & base plate (1632) is achieved by said linear guide assembly (1422) and ball screw assembly (1412).

[0032] Referring to FIG 2, the longitudinal platform (1640) provides a base to the battery module (1570). The longitudinal platform may have an insulation layer (1652) to provide electrical insulation to the battery module (1570). The battery module (1570) is mounted on the longitudinal platform (1640) with a primary battery clamp (1650), a secondary battery clamp (1651) and a module locator (1641). The primary battery clamp (1650) is designed to provide a fine adjustment of battery module (1570) on the longitudinal platform (1640). Similarly, the secondary battery clamp (1651) is designed to provide a coarse adjustment of battery module (1570) on the longitudinal platform (1640). As used herein, “fine adjustment” refers to positional adjustment of battery module with respect to the longitudinal platform in relatively small step sizes and “coarse adjustment” refers to positional adjustment of battery module with respect to the longitudinal platform in relatively big step sizes. Further, a module locator (1641) is provided to lock the position of the battery module (1570) on the longitudinal platform (1640).

[0033] Referring to FIG 3A & FIG 3B, the electrode head (1100) comprises two electrodes (1110) of opposite electrical polarity. Each electrode (1110) is further coupled to an electrode tip (1120). Electrodes (1110) and electrode tips (1120) are metallic bodies to allow flow of electrical current required for resistance welding. Further, the electrodes (1110) are coupled to wire lugs (1362), wherein, the wire lugs (1362) are further coupled to wires for electrical input required for resistance welding. Further, the electrodes (1110) are coupled to a compression mechanism (1300) comprising of springs (1310) mounted on a spring shafts (1320). The spring shafts (1320) are threaded rods and are further coupled to preloaders (1341), wherein, the preloaders (1341) can rotate over the threaded part of spring shafts (1320) thus making the springs (1310) preload as it rotates. The preloaders (1341) are further coupled to preloader locks (1342), wherein, the preloader locks (1342) are configured to stop any undesired rotation of the preloader (1341) arising due to vibrations or unnecessary human intervention. The compression mechanism (1300) further comprises guide rods (1350) which slide within linear bearings (1361), thus restricting the motion of electrodes(1110) to linear motion only. An insulation layer in a form of insulating bushes (1351) may be provided to electrically insulate the electrodes (1110) with the spring shafts (1320) and the guide rods (1350). The springs (1310), the spring shafts (1320), the preloaders (1341), the preloader locks (1342), the guide rods (1350), the linear bearings (1361), and the insulating bushes (1351) are structurally supported by a housing block (1360). The housing block (1360) may further comprise an alignment assembly (1130) comprising a laser light (1131) and a laser retainer (1132). The laser retainer (1132) is coupled to the housing block (1360) and the laser (1131) is mounted in the laser retainer (1132). The laser (1131) is suitably positioned such that the battery cell (1510) and conductor (1200) can be aligned with the electrode tips (1120) without any physical contact.

[0034] Referring to FIG 4, a coordinate system for the battery module manufacturing system (1000) is defined using a welding axis (1810), a lateral axis (1820) and a longitudinal axis (1830). The welding axis (1810) is an imaginary line normal to the welding surface of the battery cell. The linear motion of head platform (1610) is carried along said welding axis (1810). Further, the lateral axis (1820) is an imaginary line at an angle alpha (1910) with respect to the welding axis (1810). The angle alpha (1910) is predefined during the design of battery module manufacturing system (1000). The linear motion of lateral platform (1620) is carried along said lateral axis (1820). Similarly, the longitudinal axis (1830) is an imaginary line at an angle beta (1920) with respect to the welding axis (1810). The angle beta (1920) is predefined during the design of battery module manufacturing system (1000). The linear motion of longitudinal platform (1640) is carried along said longitudinal axis (1830). Furthermore, the lateral axis (1820) and the longitudinal axis (1830) are at an angle gamma (1930) with respect to each other. Thus, the three axes - welding axis (1810), lateral axis (1820), longitudinal axis (1830) form a coordinate system for the battery module manufacturing system (1000). The angles alpha (1910), beta (1920) and gamma (1930) may be 90 degrees each, thus making the welding axis (1810), lateral axis (1820), longitudinal axis (1830) mutually perpendicular.

[0035] Further, referring back to FIG 1A & FIG 1B, the ball screw assembly (1410) is coupled to an electrical motor (1750) through a coupler (1430). The electrical motor (1750) provides rotational motion to the ball screw assembly (1410), which is then translated to a linear motion of the head platform (1610) along the welding axis (1810). Similarly, the ball screw assembly (1411) is coupled to another electrical motor (1751) through another coupler (1431). The electrical motor (1751) provides rotational motion to the ball screw assembly (1411), which is then translated to a linear motion of the lateral platform (1620) along the lateral axis (1820). Similarly, the ball screw assembly (1412) is coupled to another electrical motor (1752) through another coupler (1432). The electrical motor (1752) provides rotational motion to the ball screw assembly (1412), which is then translated to a linear motion of the longitudinal platform (1640) along the longitudinal axis (1830). The couplers (1430), (1431) & (1432) are configured to transfer the rotation of the electrical motors (1750), (1751) & (1752) to the ball screw assemblies (1410), (1411) & (1412) respectively even with slight misalignment arising out of manufacturing defects or incorrect tolerances.

[0036] The electrical motors (1750), (1751) & (1752) are electrically coupled to an electronic control unit (1710) to obtain the desired rotation. A program can be dumped in the electronic control unit (1710) which has user inputs such as Toolpath (1780) & Welding parameters (1781). As used herein, a toolpath is a path through space that the electrode tips (1120) will follow on its way to produce the desired resistance welding sequence. Also, the welding parameters (1781) may be welding current and time duration of the resistance welding or other parameters known in the art. The electronic control unit (1710) is powered by a Power unit (1730) which can either have batteries or can take the electrical power from an external electrical grid. Furthermore, an energy storage system (1720) is provided, wherein, the energy storage system (1720) comprises capacitors (1722) & transistors (1721). As used herein, capacitors are electronic devices which can store certain amount of charge, thus used in energy storage applications, whereas, transistors are electronic devices which can switch electrical power, thus used in switching applications. The energy storage system (1720) is electrically coupled to electrodes (1110) through the wire lugs (1150), thus providing required welding current to the electrodes (1110). The energy storage system (1720) is operated by the electronic control unit (1710). Once the electronic control unit (1720) commands the energy storage unit (1720) to supply welding current, the capacitors (1722) are discharged through the said transistors (1721). The capacitors (1722) are recharged by the power unit (1730) for the next welding operation and this charging discharging process is carried on for each weld.

[0037] Further, position sensors (1760) may be implemented to locate the position of the head platform (1610), the lateral platform (1620), and the longitudinal platform (1640). The position sensors (1760) are electrically coupled to the electronic control unit (1710) and generate a fault signal in case undesired motion occurs in the said head platform (1610), the lateral platform (1620), and the longitudinal platform (1640). Thus, the electronic control unit (1710) pauses further motion of the electrical motors (1750), (1751), and (1752) and in turn pauses motion of said platforms. Any undesired motion can arise due to incorrect program in electronic control unit (1710) or other possible reasons and can damage the battery module (1570) or the battery module manufacturing system (1000) itself. In case the position sensors (1760) fail to locate the position, mechanical stops (1440) may be implemented as a backup safety option. The mechanical stops (1440) may be coupled to the linear guide assemblies (1420), (1421), and (1422) and can stop the motion mechanically.

[0038] In accordance with the second embodiment of the present invention, FIG 5 illustrates possible steps of manufacturing a battery module (1570) using the battery module manufacturing system (1000). As shown in flowchart (5000), first step (5010) is to program the electronic control unit (1710). The first step (5010) can be alternatively achieved by dumping an existing program in the electronic control unit (1710). The program generates a desired tool path (1780) and welding parameters (1781). Second step (5020) involves assembly of battery cells (1510) into the support structure (1520) to form a battery module (1570). The battery module (1570) is then suitably placed on the longitudinal platform (1640) in third step (5030). The position of said battery module (1570) is then fixed on the longitudinal platform (1640) using the primary battery clamp (1650), the secondary battery clamp (1651), and the module locator (1641). Fourth Step (5040) involves running the program to achieve resistance welding of conductors (1200) on the battery cells (1510). Once the resistance welding of the battery module (1570) is completed, the battery module (1570) shall be removed from the battery module manufacturing system (1000) as illustrated in fifth step (5050). The welding parameters (1781) must be altered if the next battery module (1570) is not identical to the previous one. Thus, the electronic control unit (1710) shall be reprogrammed, in accordance with the first step (5010), to meet the requirements for the nonidentical battery module (1570). If the next battery module (1570) is identical to the previous battery module (1570), the first step (5010) can be skipped for repeated resistance welding of the battery modules (1570) as illustrated using logic block (5060).

[0039] In accordance with the third embodiment of the present invention, FIG 6 illustrates set of steps for manufacturing multiple battery modules (1570) simultaneously using the said battery module manufacturing system (1000). As shown in flowchart (6000), first step (6010) is to program the electronic control unit (1710). The first step (6010) can be alternatively achieved by dumping an existing program in the electronic control unit (1710). The program generates a desired tool path (1780) in loop and welding parameters (1781) for multiple battery modules (1570). Second step (6020) involves suitably placing the pre-assembled battery modules (1570) on the longitudinal platform (1640). The position of battery modules (1570) is then fixed on the longitudinal platform (1640) using the one or more primary battery clamps (1650), secondary battery clamps (1651), and module locators (1641). Third Step (6030) involves running the program to achieve resistance welding of conductors (1200) on the battery cells (1510). Once the resistance welding of one battery module (1570) is completed, the battery module (1570) shall be replaced with a new identical battery module (1570) while the other battery modules (1570) are being resistance welded, thus keeping the process of manufacturing continuous, as illustrated in fourth step (6040).

[0040] While specific language has been used to describe the disclosure, any limitations arising on account of the same are not intended. As would be apparent to a person skilled in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein.

[0041] The figures and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. For example, orders of processes described herein may be changed and are not limited to the manner described herein. The scope of embodiments is by no means limited by these specific examples. Numerous variations, whether explicitly given in the specification or not, such as differences in structure, dimension, and use of material, are possible. The scope of embodiments is at least as broad as given by the following claims.