Abstract: Techniques are provided for electrically connecting groups of battery cells within a traction battery pack. The battery cells within each groping may include cell tab terminals of a common length for direct welding relative to a cross-member assembly. Groups of cell tab terminals may be received through cell tab openings of the cross-member assembly and then bent into place relative to a backing tab for welding. The cross-member assembly may include various lead-in and bending features that facilitate cell tab terminal bending and welding.

Abstract: Battery cell grouping solutions are disclosed for assembling traction battery packs that include cell-to-pack battery systems. A cell grouping assembly may be utilized to establish a common datum reference plane relative to multiple groupings of battery cells. An exemplary assembly method may include positioning the groupings of battery cells relative to the cell grouping assembly, and then applying a compressive force to the groupings of battery cells to provide cell stacks of the cell-to-pack battery system. The grouped cell stacks may then be located to an enclosure tray of the traction battery pack.

Abstract: Bus bar welding solutions are disclosed for electrically connecting bus bars to battery cell terminals within a battery system. An exemplary method may include performing weld repair operations. The weld repair operations may include creating a repair weld bead at a weld repair zone of the bus bar. The weld repair zone may include an area of the bus bar that is covered by a pressing device during a pressing operation and a primary welding operation of the method.

Abstract: Manufacturing processes are disclosed for assembling traction battery packs that include cell-to-pack battery systems. An exemplary assembly method includes inserting a cell matrix of the cell-to-pack battery system into a cell-compressing opening of an enclosure tray using a top-down approach. The method may include compressing a plurality of cell stacks to a desired length, compressing the cell stacks together in a transverse direction to form the cell matrix, and then installing the cell matrix as a single unit into the cell-compressing opening of the enclosure tray.

Abstract: 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.

Abstract: A traction battery pack includes a cell-to-pack battery system. A selectable shim system may be used to augment a compressive load applied to one or more cell stacks of the cell-to-pack battery system. A method of assembling the traction battery pack may include measuring a first dimension associated with each cell stack of the cell-to-pack battery system, measuring a second dimension associated with an enclosure tray, and selecting an appropriately sized shim of the selectable shim system for applying a desired amount of compression to the battery cells of each cell stack when the cell stack is received within the enclosure tray.