Abstract: Presented are metalworking systems for forming metallic workpieces, methods for making/operating such metalworking systems, and battery module cell tabs bent by a multistage cluster-and-bend press. A metalworking system includes a grouping tool and a contouring tool that both align adjacent a workpiece support structure, such as a base plate of a battery module housing buttressing a stack of battery pouch cells. The grouping tool, which may include a first reciprocating plunger or plunger head, presses together a stack of metallic workpieces to thereby form a workpiece set having a first bend profile and a first length. The contouring tool, which may include a second reciprocating plunger or a pair of plunger fingers mounted on the plunger head, is attached to the grouping tool and bends the workpiece set to a second bend profile, distinct from the first bend profile, and a second set length, shorter than the first set length.

Abstract: Presented are metalworking systems for joining metallic workpieces, methods for forming and welding such workpieces, and lithium-ion battery pouch cells with anodized aluminum tabs joined via knurling and laser welding. A method for laser welding abutting sections of a workpiece or stackup of workpieces includes receiving, via a workpiece support frame, one or more metallic workpieces each with a surface having applied thereto a treatment layer. This treatment layer releases a gas during welding. A metalworking device forms a knurl pattern into the workpiece surface with the treatment layer. The knurl pattern includes a network of channels, such as one or more series of mutually parallel, rectilinear vent channels, designed to exhaust therethrough the gas released from a welded section of the treatment layer. A laser welding device thereafter welds a joint region of the surface(s) of the one or more metallic workpiece with the knurl pattern.

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: Presented are metalworking systems for forming metallic workpieces, methods for making such workpieces and methods for operating such systems, and battery cell tabs bent by a multistage plunger press. A metalworking system includes a plunger fixture that mounts adjacent metallic workpieces, and a plunger head movably mounted to the plunger fixture to move between activated and deactivated positions. A first row of plunger fingers is mounted to the plunger head and moves in one direction to press against and bend one metallic workpiece a predefined bend angle. Likewise, a second row of plunger fingers is mounted to the plunger head and moves in an opposite direction to press against and bend another metallic workpiece another predefined bend angle. The plunger head then moves to the activated position, in tandem with the plunger fingers bending the metallic workpieces, to cause the plunger fingers to bend the workpieces additional respective bend angles.

Abstract: A tooling system is configured to align and assemble a battery module having a plurality of battery cells arranged in a stack. Each battery cell has a flexible electrical terminal arranged along a respective terminal axis, and wherein the terminal axes are parallel to one another. The system includes a tooling fixture defining at least one Y-shape slit having a V-collector culminating in a slot arranged along a slot axis. Each V-collector is configured to capture the terminals of at least two battery cells. Each slot is configured to group the captured terminals when the slot axis is parallel to the terminal axes and the fixture engages the battery module. The system also includes a mechanism configured to apply a first force to the fixture along the slot axis to engage the battery module with the fixture. The mechanism thereby groups and aligns the captured terminals within the slot.

Abstract: Presented are metalworking systems for forming metallic workpieces, methods for making/operating such systems, and battery packs with cell terminals bent by a two-stage plunger press. A metalworking system includes a first plunger with a plunger cavity extending through the first plunger's body, and one or more die cavities recessed into the first plunger's contact face. The die cavity includes one surface that contacts and bends a first workpiece a first angle, and another surface that contacts and bends a second workpiece a second angle. A second plunger includes one or more die cavities recessed into the second plunger's contact face. This die cavity includes one surface that contacts and bends the first workpiece a third angle, and another surface that contacts and bends the second workpiece a fourth angle. The second plunger passes through the plunger cavity such that the first and second plungers bend the metallic workpieces in tandem.

Abstract: Presented are metalworking systems for forming metallic workpieces, methods for making/operating such metalworking systems, and battery module cell tabs bent by a multistage cluster-and-bend press. A metalworking system includes a grouping tool and a contouring tool that both align adjacent a workpiece support structure, such as a base plate of a battery module housing buttressing a stack of battery pouch cells. The grouping tool, which may include a first reciprocating plunger or plunger head, presses together a stack of metallic workpieces to thereby form a workpiece set having a first bend profile and a first length. The contouring tool, which may include a second reciprocating plunger or a pair of plunger fingers mounted on the plunger head, is attached to the grouping tool and bends the workpiece set to a second bend profile, distinct from the first bend profile, and a second set length, shorter than the first set length.

Abstract: A tooling system is configured to align and assemble a battery module having a plurality of battery cells arranged in a stack. Each battery cell has a flexible electrical terminal arranged along a respective terminal axis, and wherein the terminal axes are parallel to one another. The system includes a tooling fixture defining at least one Y-shape s lit having a V-collector culminating in a slot arranged along a slot axis. Each V-collector is configured to capture the terminals of at least two battery cells. Each slot is configured to group the captured terminals when the slot axis is parallel to the terminal axes and the fixture engages the battery module. The system also includes a mechanism configured to apply a first force to the fixture along the slot axis to engage the battery module with the fixture. The mechanism thereby groups and aligns the captured terminals within the slot.

Abstract: Presented are metalworking systems for forming metallic workpieces, methods for making such workpieces and methods for operating such systems, and battery cell tabs bent by a multistage plunger press. A metalworking system includes a plunger fixture that mounts adjacent metallic workpieces, and a plunger head movably mounted to the plunger fixture to move between activated and deactivated positions. A first row of plunger fingers is mounted to the plunger head and moves in one direction to press against and bend one metallic workpiece a predefined bend angle. Likewise, a second row of plunger fingers is mounted to the plunger head and moves in an opposite direction to press against and bend another metallic workpiece another predefined bend angle. The plunger head then moves to the activated position, in tandem with the plunger fingers bending the metallic workpieces, to cause the plunger fingers to bend the workpieces additional respective bend angles.

Abstract: Presented are metalworking systems for joining metallic workpieces, methods for forming and welding such workpieces, and lithium-ion battery pouch cells with anodized aluminum tabs joined via knurling and laser welding. A method for laser welding abutting sections of a workpiece or stackup of workpieces includes receiving, via a workpiece support frame, one or more metallic workpieces each with a surface having applied thereto a treatment layer. This treatment layer releases a gas during welding. A metalworking device forms a knurl pattern into the workpiece surface with the treatment layer. The knurl pattern includes a network of channels, such as one or more series of mutually parallel, rectilinear vent channels, designed to exhaust therethrough the gas released from a welded section of the treatment layer. A laser welding device thereafter welds a joint region of the surface(s) of the one or more metallic workpiece with the knurl pattern.

Abstract: Presented are metalworking systems for forming metallic workpieces, methods for making/operating such systems, and battery packs with cell terminals bent by a two-stage plunger press. A metalworking system includes a first plunger with a plunger cavity extending through the first plunger's body, and one or more die cavities recessed into the first plunger's contact face. The die cavity includes one surface that contacts and bends a first workpiece a first angle, and another surface that contacts and bends a second workpiece a second angle. A second plunger includes one or more die cavities recessed into the second plunger's contact face. This die cavity includes one surface that contacts and bends the first workpiece a third angle, and another surface that contacts and bends the second workpiece a fourth angle. The second plunger passes through the plunger cavity such that the first and second plungers bend the metallic workpieces in tandem.

Abstract: A retention socket is configured to hold a non-ferrous metallic fastener and includes a socket body defining a cavity shaped to receive a head of the non-ferrous metallic fastener. The retention socket further includes a mechanical retaining feature coupled to the socket body to removably couple the non-ferrous metallic fastener to the socket body without the aid of magnetic forces.

Abstract: Tooling systems and methods may be employed for installing a plurality of visually similar threaded fasteners to a plurality of assemblies. Each of the assemblies may have one or more threaded mating surfaces configured to receive different types of threaded fasteners, e.g., formed of different materials. The tooling system may include a tool(s) having a drive surface configured to install a threaded fastener by relative rotation of a gripping feature of the fastener with respect to a corresponding mating thread, each tool having a sensor disposed adjacent the drive surface and configured to detect a presence of the first material when a gripping feature of the one of the threaded fasteners of the first fastener type is positioned on the drive surface. The tooling system may also include a controller configured to determine the type of the selected threaded fastener based upon the sensor.

Abstract: A system for evaluating battery connection quality in one or more battery modules of a battery assembly includes a battery testing unit having a housing including an upper surface and a lower surface. A plurality of testing modules are disposed on the lower surface of the housing to communicate with and electrically contact the one or more battery modules of the battery assembly. The plurality of testing modules each include at least one connector extending from a lower surface of the testing module and at least one contact disposed on one or more side surfaces of the testing module. A controller is in electrical communication with the at least one connector and at least one contacts to simultaneously evaluate voltage and resistance measurements of the one or more battery modules of the battery assembly.

Abstract: Tooling systems and methods may be employed for installing a plurality of visually similar threaded fasteners to a plurality of assemblies. Each of the assemblies may have one or more threaded mating surfaces configured to receive different types of threaded fasteners, e.g., formed of different materials. The tooling system may include a tool(s) having a drive surface configured to install a threaded fastener by relative rotation of a gripping feature of the fastener with respect to a corresponding mating thread, each tool having a sensor disposed adjacent the drive surface and configured to detect a presence of the first material when a gripping feature of the one of the threaded fasteners of the first fastener type is positioned on the drive surface. The tooling system may also include a controller configured to determine the type of the selected threaded fastener based upon the sensor.

Abstract: A method for assembling a battery section having an interconnect board (ICB) and multiple parallel battery cell tab sets arranged in a column includes positioning the battery section adjacent and parallel to an elongated guide rail. The method includes engaging a comb assembly with the guide rail, with the comb assembly having comb teeth extending orthogonally from a base. The comb assembly is translated along the guide rail toward the column, while the comb assembly remains engaged with the rail, until the base is adjacent to the column. Thereafter, each cell tab set is received between comb teeth, such that the cell tab sets are separated from, and aligned with respect to, each other. The ICB is decked to the battery section, and the comb assembly is translated along the guide rail away from the column after decking the ICB.

Abstract: A retention socket is configured to hold a non-ferrous metallic fastener and includes a socket body defining a cavity shaped to receive a head of the non-ferrous metallic fastener. The retention socket further includes a mechanical retaining feature coupled to the socket body to removably couple the non-ferrous metallic fastener to the socket body without the aid of magnetic forces.

Abstract: A system for evaluating battery connection quality in one or more battery modules of a battery assembly includes a battery testing unit having a housing including an upper surface and a lower surface. A plurality of testing modules are disposed on the lower surface of the housing to communicate with and electrically contact the one or more battery modules of the battery assembly. The plurality of testing modules each include at least one connector extending from a lower surface of the testing module and at least one contact disposed on one or more side surfaces of the testing module. A controller is in electrical communication with the at least one connector and at least one contacts to simultaneously evaluate voltage and resistance measurements of the one or more battery modules of the battery assembly.

Abstract: A method of assembling a battery assembly includes forming battery packs, each pack including battery cells and cooling passages extending along a length of the pack, connecting terminals of each pack to a dc source and charging each pack to a desired state of charge, installing battery packs on a tray located on an automatically guided cart, using the cart to carry the battery assembly to locations where method steps are performed including performing testing for fluid leaks in a cooling circuit comprising interconnected passages of each pack on the tray and installing electric circuits in the assembly.

Abstract: A method of assembling a battery assembly includes forming battery packs, each pack including battery cells and cooling passages extending along a length of the pack, connecting terminals of each pack to a dc source and charging each pack to a desired state of charge, installing battery packs on a tray located on an automatically guided cart, using the cart to carry the battery assembly to locations where method steps are performed including performing testing for fluid leaks in a cooling circuit comprising interconnected passages of each pack on the tray and installing electric circuits in the assembly.