Abstract: A multi-level busbar for interconnecting flexible cell tabs within a battery module of a battery electric system, e.g., of a motor vehicle having a traction motor and road wheels, includes first and second busbar surfaces and an elongated step transition. The first busbar surface is arranged at a first level of the busbar and is configured to be welded to a first tab group of the cell tabs. The second busbar surface is arranged at a second level of the busbar, and configured to be welded to a second tab group of the cell tabs. The step transition has a height dimension configured to allow the first and second tab groups to overlap when folded against and welded to the busbar.

Abstract: A method includes the following steps: actuating a robotic arm to perform an action at a start position; moving the robotic arm from the start position toward a first position; determining from a vision process method if a first part from the first position will be ready to be subjected to a first action by the robotic arm once the robotic arm reaches the first position; commencing the execution of the visual processing method for determining the position deviation of the second part from the second position and the readiness of the second part to be subjected to a second action by the robotic arm once the robotic arm reaches the second position; and performing a first action on the first part using the robotic arm with the position deviation of the first part from the first position predetermined by the vision process method.

Abstract: A method for generating a candidate assembly system layout for an assembled product includes inputting a bill of materials including a list of components for the assembled product and determining a plurality of assembly patterns for the assembled product including a plurality of intermediate assemblies and sub-assemblies. A basic task layout is determined that includes assembly tasks for assembling the assembled product based upon a selected one of the assembly patterns. A whole task layout is determined based upon the basic task layout for the selected assembly pattern. Candidate assembly machines are selected for the whole task layout, and zoning constraints are identified for the candidate assembly machines related to assembly tasks. A candidate assembly system layout is generated based upon the whole task layout, the selected candidate assembly machines and the zoning constraints, from which a simulation model of a candidate assembly system is generated.

Abstract: A method includes the following steps: actuating a robotic arm to perform an action at a start position; moving the robotic arm from the start position toward a first position; determining from a vision process method if a first part from the first position will be ready to be subjected to a first action by the robotic arm once the robotic arm reaches the first position; commencing the execution of the visual processing method for determining the position deviation of the second part from the second position and the readiness of the second part to be subjected to a second action by the robotic arm once the robotic arm reaches the second position; and performing a first action on the first part using the robotic arm with the position deviation of the first part from the first position predetermined by the vision process method.

Abstract: A repeating frame assembly for a battery pack includes a first cooling frame member having a first electrically conductive connection terminal adjacent a first end of the first cooling frame member. The connection terminal includes a top leg forming at least a portion of the first surface of the first cooling frame member and a bottom leg forming at least a portion of the second surface of the first cooling frame member. A first electrically conductive tab of a first battery cell is attached to the top leg of the first electrically conductive connection terminal. A second battery cell may be contained within a second cooling frame member or a first spacer frame member having a second electrically conductive connection terminal adjacent a first end thereof for providing a compression joint having a low resistance electrical connection to the second tab of the first battery cell.

Abstract: A battery cell tab is described. The battery cell tab is anodized on one end and has a metal coating on the other end. Battery cells and methods of making battery cell tabs are also described.

Abstract: A repeating frame assembly for a battery pack includes a first cooling frame member having a first electrically conductive connection terminal adjacent a first end of the first cooling frame member. The connection terminal includes a top leg forming at least a portion of the first surface of the first cooling frame member and a bottom leg forming at least a portion of the second surface of the first cooling frame member. A first electrically conductive tab of a first battery cell is attached to the top leg of the first electrically conductive connection terminal. A second battery cell may be contained within a second cooling frame member or a first spacer frame member having a second electrically conductive connection terminal adjacent a first end thereof for providing a compression joint having a low resistance electrical connection to the second tab of the first battery cell.

Abstract: A battery pack assembly includes a first battery cell having a first electrical connection tab formed of a first material, a second battery cell having a first electrical connection tab formed of a second material, and a metal clad connection terminal having a first surface formed of the first material and a second surface formed of the second material, wherein the first electrical connection tab of the first battery cell is electrically connected to the first surface of the metal clad connection terminal, and the first electrical connection tab of the second battery cell is electrically connected to the second surface of the metal clad connection terminal.

Abstract: A battery cell tab is described. The battery cell tab is anodized on one end and has a metal coating on the other end. Battery cells and methods of making battery cell tabs are also described.