热电池电堆极线弯折力学性能研究

Research on the Mechanical Properties of Electrode Tab Bending in Thermal Battery Stacks

摘要: 针对热电池自动化装配中极线弯折工序的精度与可靠性需求，设计了一种自动化极线弯折机构，并对其结构与性能展开了系统研究。首先，基于库伦摩擦定律与金属塑性弯曲理论建立了力学模型，分析了弯折机构压轮下压力对极线弯折成形效果的影响规律。在此基础上，利用Abaqus有限元软件构建弯折过程的仿真模型，模拟不同压力条件下极耳的变形行为，并对弯折质量与贴合度进行评估。仿真结果表明，合理的压轮下压力不仅能够保证极耳与电堆表面平整贴合，还能避免损伤云母片绝缘层，从而满足装配工艺要求。最后，搭建实验平台并开展实际弯折实验，结果验证了力学模型与仿真分析的正确性和可行性，为热电池自动化装配工艺设计提供了理论支撑与工程参考。

Abstract: To address the precision and reliability requirements of the electrode tab bending process in automated thermal battery assembly, an automated electrode tab bending mechanism was designed, and its structure and performance were systematically studied. First, a mechanical model was established based on Coulomb’s friction law and metal plastic bending theory to analyze the influence of the pressure roller’s downward force on the electrode tab bending forming effect. Based on this, a simulation model of the bending process was constructed using Abaqus finite element software to simulate the deformation behavior of the electrode tabs under different pressure conditions and to evaluate the bending quality and fit. The simulation results showed that a reasonable downward force of the pressure roller can not only ensure a flat fit between the electrode tab and the battery stack surface but also avoid damaging the mica insulation layer, thus meeting the assembly process requirements. Finally, an experimental platform was built, and actual bending experiments were conducted. The results verified the correctness and feasibility of the mechanical model and simulation analysis, providing theoretical support and engineering reference for the design of the automated thermal battery assembly process.