Patent Publication Number: US-2023136663-A1

Title: Automated battery assembly systems and related methods, including method of securing contact tabs

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Pat. Application No. 63/255,949 filed on Oct. 14, 2021. The entire contents of U.S. Provisional Pat. Application No. 63/255,949 is hereby incorporated by reference for all purposes. 
    
    
     FIELD 
     The described embodiments relate to systems and methods for assembling batteries, and in particular, to systems and methods for assembling batteries in an automated process in which contact tabs of multiple cathodes of anodes are secured together. 
     BACKGROUND 
     Some battery technologies have a layered structure with multiple electrode plates stacked together. Such battery technologies are commonly used in electric vehicles and energy grid storage. As the world transitions away from fossil fuels and towards more sustainable electrification, the demand for such batteries is growing. 
     Batteries can be assembled in a traditional assembly line in which an unfinished battery is moved to multiple stations for the assembly of various battery components. In some cases, only one component is added to the unfinished battery at each station, resulting in a large number of stations to complete a battery having a layered structure. Each station along the assembly line increases the floor space required for the assembly line. However, adding different components at a single station can increase complexity and production time. 
     Moreover, in some cases electrically connecting different portions of a battery (such as the anodes or cathodes of a battery) can be cumbersome. 
     SUMMARY 
     The various embodiments described herein generally related to methods (and associated systems configured to implement the methods) for assembling batteries in an automated process. 
     In accordance with a broad aspect, there is provided an automated battery assembly system. The system includes a closed-loop transport track, a plurality of stations along the track, and a control system. The closed-loop transport track includes a plurality of pallets. Each pallet receives at least one battery stack and is moveable along the track. The plurality of stations include a plurality of assembly stations for adding at least one battery component to a battery stack held on a pallet, and at least one transfer station for unloading a completed battery stack from the pallet. The completed battery stack includes a plurality of cells having a particular composition. The control system moves the pallets to the plurality of stations in a predetermined sequence to assemble the completed battery stack. The predetermined sequence can include a plurality of revolutions around the track. Each of the battery cells include at least one of a cathode plate, an anode plate, and a separator plate. The particular composition relates to an arrangement of the at least one of a cathode plate, an anode plate, and a separator plate between a lower plate and an upper plate. 
     In at least one embodiment, the at least one battery component can be added to the battery stack in each revolution of the predetermined sequence. 
     In at least one embodiment, the at least one transfer station can load a carrier to the pallet. 
     In at least one embodiment, an assembly station can load a lower plate to a carrier on the track. 
     In at least one embodiment, the at least one transfer station loading a carrier to a pallet can include the at least one transfer station loading the carrier to the pallet with a lower plate being held therein. 
     In at least one embodiment, the at least one transfer station unloading the completed battery stack from the track can include the at least one transfer station unloading the carrier from the track, the completed battery stack being held therein. 
     In at least one embodiment, the at least one battery component added by an assembly station can be one of a cathode plate, an anode plate, a separator plate, a block, a pass through conductor, a block-mounting flange, the lower plate, or the upper plate. 
     In at least one embodiment, the control system can reduce the speed of the pallets as the pallets approach the assembly station to receive a battery component. 
     In at least one embodiment, the control system can stop the pallets at an assembly station to receive a battery component and then resume the movement of the pallets after the battery component is added to the battery stack. 
     In at least one embodiment, the control system can move the plurality of pallets around the track synchronously. In at least one embodiment, the control system can move the plurality of pallets around the track asynchronously. 
     In at least one embodiment, the battery stack can receive battery components in a specific order in each revolution of the predetermined sequence. 
     In at least one embodiment, the battery stack can receive battery components in a different specific order in each revolution of the predetermined sequence. 
     In at least one embodiment, the number of the plurality of pallets can be greater than the number of the plurality of assembly stations. 
     In at least one embodiment, the track can include a plurality of pallets, the plurality of pallets receiving at least one carrier. 
     In at least one embodiment, each of the battery cells can further include a second separator plate. 
     In at least one embodiment, the particular composition can include the anode plate on top of the lower plate, a first separator plate on top of the anode plate, the cathode plate on top of the first separator plate, and a second separator plate on top of the cathode plate. 
     In accordance with another broad aspect, an automated method of mass assembling battery stacks is provided. The method involves moving a plurality of pallets to a plurality of stations located along a closed-loop transport track in a predetermined sequence. The plurality of stations include a plurality of assembly stations and at least one transfer station. The predetermined sequence includes a plurality of revolutions around the track. The method further involves receiving, on the plurality of pallets, a plurality of battery components from the plurality of assembly stations to assemble a plurality of battery stacks. Each battery stack of the plurality of battery stacks includes a plurality of cells, each cell of the plurality of cells having a particular composition. Each of the cells includes at least one of a cathode plate, an anode plate, and a separator plate. The particular composition is an arrangement of the at least one of a cathode plate, an anode plate, and a separator plate between a lower plate and an upper plate. The method also involves unloading, by the at least one transfer station, the plurality of battery stacks from the plurality of pallets. 
     In at least one embodiment, the method can further involve adding, by the plurality of stations, at least one battery component to the battery stack in each revolution of the predetermined sequence. 
     In at least one embodiment, the method can further involve loading, by the at least one transfer station, a carrier to the pallet. 
     In at least one embodiment, the method can further involve loading, by an assembly station, a lower plate to the carrier on the track. 
     In at least one embodiment, the method can further involve loading, by the at least one transfer station, the carrier to the pallet, the carrier with a lower plate being held therein. 
     In at least one embodiment, the method can further involve unloading, by the at least one transfer station, the carrier from the track, the completed battery stack being held therein. 
     In at least one embodiment, the method can further involve adding, by an assembly station, the at least one battery component, wherein the at least one battery component is one of a cathode plate, an anode plate, a separator plate, a block, a pass through conductor, a block-mounting flange, the lower plate, or the upper plate. 
     In at least one embodiment, the method can further involve reducing the speed of the pallets as they approach the assembly station to receive a battery component. 
     In at least one embodiment, the method can further involve stopping the pallets at an assembly station to receive a battery component and moving the pallets after the battery component is added to the battery stack. 
     In at least one embodiment, the method can further involve moving the plurality of pallets around the track synchronously. 
     In at least one embodiment, the method can further involve moving the plurality of pallets around the track asynchronously. 
     In at least one embodiment, the method can further involve receiving the battery components in a specific order in each revolution of the predetermined sequence. 
     In at least one embodiment, the method can further involve receiving the battery components in a different specific order in each revolution of the predetermined sequence. 
     In at least one embodiment, the number of the plurality of pallets can be greater than the number of the plurality of assembly stations. 
     In at least one embodiment, the track can include a plurality of pallets, the plurality of pallets receiving at least one carrier. 
     In at least one embodiment, each of the battery cells can further include a second separator plate. 
     In at least one embodiment, the particular composition can include the anode plate on top of the lower plate, a first separator plate on top of the anode plate, the cathode plate on top of the first separator plate, and the second separator plate on top of the cathode plate. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Several embodiments will now be described in detail with reference to the drawings, in which: 
         FIG.  1    is a schematic diagram of an example automated battery assembly system, in accordance with an embodiment; 
         FIG.  2 A  is a perspective view of an example carrier, in accordance with an embodiment; 
         FIG.  2 B  is a perspective view of the carrier of  FIG.  2 A  holding an unfinished battery stack; 
         FIG.  2 C  is a perspective view of the carrier of  FIG.  2 A  holding a completed battery stack; 
         FIG.  3    is a view of an example battery cell, in accordance with an embodiment; 
         FIG.  4    is a schematic diagram of another example automated battery assembly system, in accordance with an embodiment; 
         FIG.  5    is a flowchart of an example method for assembling a battery, in accordance with an embodiment; 
         FIG.  6    is a schematic of a tab bending machine according to another embodiment; 
         FIG.  7    is a schematic of an assembly having two anodes according to one embodiment; 
         FIG.  8    is a schematic of an assembly having two cathodes according to one embodiment; 
         FIG.  9    is a schematic of an assembly having three anodes according to another embodiment; and 
         FIG.  10    is a schematic of an assembly having three cathodes according to another embodiment. 
     
    
    
     The drawings, described below, are provided for purposes of illustration, and not of limitation, of the aspects and features of various examples of embodiments described herein. For simplicity and clarity of illustration, elements shown in the drawings have not necessarily been drawn to scale. The dimensions of some of the elements may be exaggerated relative to other elements for clarity. It will be appreciated that for simplicity and clarity of illustration, where considered appropriate, reference numerals may be repeated among the drawings to indicate corresponding or analogous elements or steps. 
     DESCRIPTION OF VARIOUS EMBODIMENTS 
     The various embodiments described herein generally relate to automated battery assembly systems and related methods. In some examples, the various embodiments described herein generally relate to automated systems and related methods of assembling a battery having a layered structure. 
     Reference is now made to  FIG.  1   , which shows a schematic diagram of an example automated battery assembly system  100 . The automated battery assembly station includes a closed-loop transport track  102 , a control system  104 , and a plurality of stations  108   a ,  108   b ,  108   c ,  108   d , and  108   e , (hereinafter referred to as “ 108   a - e ”),  110   a  and  110   b  (hereinafter referred to as “ 110   a - b ”) located adjacent to the closed-loop transport track  102 . Although example system  100  is shown with seven stations  108   a - e ,  110   a - b , fewer or more stations can be included. Although stations  108   a - e ,  110   a - b  are shown as being located around the closed-loop transport track  102 , any one or more stations can be located within the closed-loop transport track  102 . 
     The closed-loop transport track  102  can move one or more unfinished battery stacks among the plurality of stations  108   a - e ,  110   a - b  to successively assemble the battery stacks. Furthermore, the unfinished battery stacks can be moved to complete multiple revolutions around the closed-loop transport track  102  for assembly. In at least one embodiment, the closed-loop transport track  102  can be a conveyor. 
     In at least one embodiment, pallets, such as pallets  106   a ,  106   b ,  106   c ,  106   d ,  106   e ,  106   f ,  106   g ,  106   h ,  106   i , and  106   j  (hereinafter referred to as “pallets  106   a - j ”), can be mounted to the closed-loop transport track  102  to receive and transport the battery stacks. The pallets  106   a - j  can be fixedly mounted to the conveyor. As shown in  FIG.  1   , there can be 10 pallets  106   a - j  on the conveyor. However, any number of pallets  106   a - j  can be included. Although  FIG.  1    shows a greater number of pallets  106   a - j  than stations  108   a - e ,  110   a - b , there can be fewer pallets than stations, or an equal number of pallets and stations. Furthermore, each pallet  106   a - j  can receive and transport one or more battery stacks. 
     In at least one embodiment, pallets  106   a - j  can receive battery stacks held in carriers. That is, the pallets  106   a - j  can receive and transport carriers holding battery stacks therein. 
     Reference is now made to  FIGS.  2 A to  2 C , which shows an example carrier  200 . As can be seen, carrier  200  can include a platform  202  on which the electrode plates can be placed. Carrier  200  can also have plurality of vertically extending members  204   a - 204   d  to hold the electrode plates in the area between the vertically extending members  204   a - 204   d . That is, the vertically extending members  204   a - 204   d  can retain the battery stack on the platform  202  as the carrier  200  is moved along the closed-loop transport track  102 . Although carrier  200  is shown with four vertically extending members  204   a - 204   d , fewer or more vertically extending members can be provided. 
     In  FIG.  2 B , the example carrier  200  holds an example unfinished battery stack  212 . As shown, the unfinished battery stack  212  can include multiple plates layered on top of one another. Each plate can be, for example, an anode plate, a cathode plate, or a separator plate. The number of plates and the particular order or sequence of the plates can vary, depending on the battery being assembled. 
     In at least one embodiment, the plates of the battery stack can have a particular shape. For example, the plates of battery stack  212  has tabs  214   a ,  214   b ,  214   c ,  214   d , and  214   f . The plurality of vertically extending members  204   a - 204   d  can be located on the platform  202  in a manner that corresponds to the geometry of the battery stack  212 . This can ensure that the plates of the battery stack are properly aligned with one another. In  FIG.  2 C , the example carrier  200  hold an example completed battery stack  222 . 
     Returning now to  FIG.  1   , the control system  104  can be configured to operate the closed-loop transport track  102  and the plurality of stations  108   a - e ,  110   a - b . In some examples, the control system  104  can move the pallets  106   a - j  along the closed-loop transport track  102  synchronously, where each pallet  106   a - j  is moved at the same speed. For example, the control system  104  can move all pallets  106   a - j  to a station  108   a - e ,  110   a - b  around the closed-loop transport track  102  and stop all pallets  106   a - j  at the respective stations  108   a - e ,  110   a - b . The control system  104  can then move all pallets  106   a - j  to the next respective station  108   a - e ,  110   a - b  around the closed-loop transport track  102 . 
     In some examples, the control system  104  can move the pallets  106   a - j  along the closed-loop transport track  102  asynchronously, where each pallet  106   a - j  is moved independently of one another. For example, the control system  104  can move pallet  106   a  to station  108   a  and pallet  106   b  to station  108   b . The process performed on a battery stack at station  108   a  may take less time than the process performed on a battery stack at station  108   b . The control system  104  may then move pallet  106   a  from station  108   a  to station  108   b , where it will then stop and wait for station  108   b  to complete the loading of the battery component to pallet  106   b . After the battery component is loaded to pallet  106   b , the control system  104  may move pallet  106   b  from station  108   b  to station  108   c  and move pallet  106   a  to station  108   b  to receive another battery component. This process may occur with any of the pallets  106   a - j  and any of the stations  108   a - e ,  110   a - b . 
     The control system  104  can control the speed of the pallets  106   a - j  as they are moved amongst the plurality of stations  108   a - e ,  110   a - b . In at least one embodiment, the control system  104  can bring the pallets  106   a - j  to a stop at the stations  108   a - e ,  110   a - b  so that the stations  108   a - e ,  110   a - b  can process the unfinished battery. In at least one embodiment, the stations  108   a - e ,  110   a - b  can process the unfinished battery while it is in motion. For example, the control system  104  can reduce the speed of the pallets  106   a - j  as they approach the stations  108   a - e ,  110   a - b  to allow the stations  108   a - e ,  110   a - b  to process the unfinished battery  108   a - e . In another example, the pallets  106   a - j  are not slowed down in order to be processed. That is, the pallets  106   a - j  may travel between stations  108   a - e ,  110   a - b  at a speed that allows the stations  108   a - e ,  110   a - b  to process the unfinished battery. 
     In at least one embodiment, a pallet  106   a - j  may not require processing at one or more stations  108   a - e ,  110   a - b . For example, the control system  104  can control the pallets  106   a - j  to bypass one or more of the plurality of stations  108   a - e ,  110   a - b  without the one or more stations  108   a - e ,  110   a - b  processing the unfinished battery. 
     The plurality of stations  108   a - e ,  110   a - b  located around the closed-loop transport track  102  can be assembly stations  108   a - e , transfer stations  110   a - b , or a combined assembly and transfer station (not shown). An assembly station  108   a - e  can process a battery stack by, for example, adding a battery component to an unfinished battery stack after the pallet  106   a - j  carrying the unfinished battery stack arrives at the assembly station  108   a - e . In another example, assembly stations  108   a - e  can perform other functions, such as trimming or welding battery components on the pallet  106   a - j  or testing portions of the unfinished or completed battery stack (e.g., leak testing). 
     In at least one embodiment, an assembly station  108   a - e  can process an unfinished battery stack by loading a particular battery component to a pallet  106   a - j . For example, a first assembly station  108   a  can add an anode plate to a battery stack while a second assembly station  108   b  can add a separator plate to the battery stack and a third assembly station  108   d  can add a cathode plate to the battery stack. In at least one embodiment, an assembly station  108   a - e  can load multiple battery components to a pallet  106   a - j . For example, assembly stations  108   b  and  108   d  can add two separator plates and two cathode plates respectively to the battery stack. 
     In at least one embodiment, an assembly station  108   a - e  can load different battery components to a pallet  106   a - j  in different instances. For example, assembly station  108   c  can add a block to a pallet  106   a - j  during a first revolution around the closed-loop transport track  102  and add a mounting flange to the same pallet  106   a - j  during a subsequent revolution around the closed-loop transport track  102 . The pallets  106   a - j  can complete multiple revolutions around the closed-loop transport track  102  before the battery stack is completed. 
     In at least one embodiment, an assembly station  108   a - e  can process more than one battery stack at a time. For example, a pallet  106   a - j  can carry more than one battery stack and the assembly station  108   a - e  can carry more than one of the same component. The assembly station  108   a - e  can add battery components to the plurality of stacks successively, without having to pick-up additional battery components, or reload the assembly station  108   a - e  with additional battery components. In another example, an assembly station  108   a - e  can receive more than one pallet  106   a - j . Similarly, the assembly station  108   a - e  can add battery components to the plurality of stacks on the plurality of pallets successively, without having to pick-up additional battery components, or reload the assembly station  108   a - e  with additional battery components. 
     In at least one embodiment, a transfer station  110   a - b  can transfer the battery stacks to and from the pallets  106   a - j . For example, a transfer station  110   a - b  can unload a completed battery stack from a pallet  106   a - j . The completed battery stack can be unloaded from the pallet  106   a - j  with the carrier  200  holding the completed battery stack therein.  108   a - e . In another example, a transfer station  110   a - b  can load a carrier  200  onto a pallet  106   a - j . In some examples, a transfer station  110   a - b  both perform both loading and unloading operations. 
     In some examples, a transfer station  110   a - b  can unload the completed battery stack from the carrier  200  itself. That is, the carrier  200  can remain on the pallet  106   a - j  of the closed-loop transport track  102 . The pallet  106   a - j  holding the carrier can then be moved, by the control system  104 , to an assembly station  108   a - e  to begin another battery stack. 
     Reference is now made to  FIG.  3   , which is an illustration of an example battery cell  300 . The battery cell  300  has a lower plate  302  and an upper plate  310 . The composition of the battery cell  300  between the lower plate  302  and the upper plate  310  can vary. As shown in  FIG.  3   , the battery cell  300  includes, from the bottom up, an anode plate  304 , a first separator plate  306   a , a cathode plate  308 , and a second separator plate  306   d . In other embodiments, fewer or more electrodes can be included. For example, another battery stack may include two separator plates between anode plate  304  and cathode plate  308 , two separator plates on top of the cathode plate  308 , or two cathode plates instead of only one cathode plate. As well, the order of the electrodes can be different. For example, separator plate  306   b  can instead be positioned on top of separator plate  306   a  and below cathode plate  308 . 
     Although not shown in  FIG.  3   , battery cells  300  can also include additional components, such as but not limited to blocks, insulators (e.g., thin insulator blocks, thick insulator blocks), conductors (e.g., feed through conductors), flanges (e.g., block-mounting flanges), nuts, studs, or tubes. 
     A battery stack can include a plurality of battery cells. For example, a battery stack can include 18 battery cells, such as example battery cell  300 . To assemble a battery stack, the pallet  106   a - j  can make multiple revolutions around the closed-loop transport track  102  to complete multiple the battery cells  300 . At various points during the assembly of the battery stack, additional battery components such as feed through conductors and/or a block-mounting flanges can be added. Such additional battery components may connect the battery cells  300 . 
     The control system  104  can move the pallets  106   a - j  in multiple revolutions around the closed-loop transport track  102 , wherein the revolutions can include different stops at assembly stations  108   a - e  each time. For example, pallet  106   a , on the first revolution around the closed-loop transport track  102 , can stop at assembly stations  108   a  and  108   b  to receive certain battery components on the battery stack. On the second revolution around the closed-loop transport track  102 , pallet  106   a  can stop at assembly stations  108   c  and  108   d  to receive different battery components on the battery stack. In some examples, each pallet  106   a - j  can have the same required stops at each assembly station  108   a - e  during each revolution around the closed-loop transport track. In some examples, each pallet  106   a - j  can have a different set of required stops at each assembly station  108   a - e  during each revolution around the closed-loop transport track. 
     Referring now to  FIG.  4   , which shows a schematic diagram of another example automated battery assembly system  400 . Similar to example system  100 , the automated battery assembly station can include a closed-loop transport track  402 , a control system  404 , and a plurality of stations located adjacent to the closed-loop transport track  402 . The plurality of stations can include assembly stations  408   a ,  408   b ,  408   c ,  408   d ,  408   e  and  408   f , (hereinafter referred to as “ 408   a - f ”) and transfer stations  410   a  and  410   b  (hereinafter referred to as “ 410   a - b ”). Although example system  400  is shown with eight stations  408   a - f ,  410   a - b , fewer or more stations can be included. Similar to system  100 , although system  400  is shown with stations  408   a - f ,  410   a - b  located around the closed-loop transport track  402 , any one or more stations can be located within the closed-loop transport track  402 . 
     Similar to transfer stations  110   a - b , transfer station  410   a  can load an unfinished battery stack to the closed-loop transport track  402 . For example, transfer station  410   a   can load a carrier, such as example carrier  200 , to a pallet, such as pallet  106   a - j , on the closed-loop transport track  402 . In at least one embodiment, the carrier  200  can be empty. In other embodiments, the carrier  200  can contain one or more battery components therein, such a lower plate  302 . 
     In at least one embodiment, the unfinished battery stack can be transported to the transfer station  410   a  by an input transport track  412 . As shown in  FIG.  4   , the input transport track  412  can be a linear conveyor. The input transport track  412  can transport the carrier  200  from a supply station  406 . The supply station  406  can provide one or more components  406   a ,  406   b ,  406   c  of the unfinished battery stack to the input transport track  412 , such as carriers  200  and lower plates  302  contained therein. 
     The system  400  can operate in manner similar to system  100  and assemble battery stacks with a plurality of battery cells, such as the example battery cell  300  shown in  FIG.  3   . 
     Similar to transfer stations  110   a - b , transfer station  410   b  can unload a completed battery stack, such as completed battery stack  222 , from a pallet on the closed-loop transport track  402 . In at least one embodiment, transfer station  410   b  can unload the completed battery stack  222  from the carrier  200  on the pallet. In other embodiments, transfer station  410   b  can unload the carrier  200  from the pallet with the completed battery stack  222  held therein. 
     Transfer station  410   b  can unload the completed battery stack  222  to a first output transport track  414   a . The first output transport track  414   a  can transport the completed battery stack  222  away from transfer station  410   b . As shown in  FIG.  4   , the first output transport track  414   a  can be a linear conveyor. In at least one embodiment, the first output transport track  414   a  can transport the carrier  200  with the completed battery stack  222  held therein to an additional assembly station  416 . Similar to assembly stations  408   a - f , the completed battery stack can be further processed at assembly station  416 . 
     In at least one embodiment, additional battery components can be added to the battery stack at assembly station  416 . For example, an upper plate  310  can be added to the battery stack at assembly station  416 . In other embodiments, the upper plate  310  can be added by assembly stations  408   a - f  while the battery stack is on the closed-loop transport track and no further assembly is performed on the completed battery stack  222  after it is unloaded from the closed-loop transport track  402 . The first output transport track  414   a  can transport the completed battery stack  222  to a collection location, such as a cart. 
     In at least one embodiment, the transfer station  410   b  can include sensors for inspecting or testing the completed battery stack to determine if the completed battery stack should be rejected for being incorrectly assembled or not meeting various quality control requirements. If the completed battery stack is a reject, the transfer station  410   b  can unload the reject to a second output transport track  414   b  instead of first output transport track  414   a . As shown in  FIG.  4   , the second output transport track  414   b  can be a linear conveyor, such as a gravity conveyor. The second output transport track  414   b  can transport rejects to a collection location, such as a bin. 
     In at least one embodiment, the additional assembly station  416  can perform the inspection or testing and load the completed battery stack to a respective collection location. 
     In at least one embodiment, a single transport track (not shown) can serve as both the input transport track  412  and the first output transport track  414   a . For example, a single transport track can transport an empty carrier  200  to the closed-loop transport track  402  and transport a carrier holding a completed battery stack  222  therein from the closed-loop transport track  402 . 
     Referring now to  FIG.  5   , illustrated is a method  500  for assembling a battery. Method  500  can be implemented by an automated battery assembly system, such as system  100  or system  400 . 
     The method  500  can involve, at step  502 , moving a plurality of pallets, such as pallets  106   a - j , to a plurality of stations, such as stations  108   a - e ,  110   a - b  located along a closed-loop transport track, such as track  102 , in a predetermined sequence. The plurality of stations can include a plurality of assembly stations, such as stations  108   a - e , and at least one transfer station, such as stations  110   a - b . The predetermined sequence includes a plurality of revolutions around the track  102 . 
     At  504 , the method can involve receiving, on the plurality of pallets  106   a - j , a plurality of battery components from the plurality of assembly stations  108   a - e  to assemble a plurality of battery stacks. Each battery stack of the plurality of battery stacks includes a plurality of cells. Each cell of the plurality of cells has a particular composition. 
     In at least one embodiment, receiving battery components on the plurality of pallets  106   a - j  at step  504  can involve adding at least one battery component to the battery stacks in each revolution of the predetermined sequence. The at least one battery component can be added by an assembly station  108   a - e . Example battery components include, but are not limited to cathode plates, anode plates, separator plates, blocks, pass through conductors, block-mounting flanges, lower plates, and upper plates. 
     Each of the cells can include at least one of a cathode plate, an anode plate, and a separator plate. For example, a cell can include at least one anode plate, two cathode plates, and four separator plates. The particular composition relates to an arrangement of the at least one of a cathode plate, an anode plate, and a separator plate between a lower plate, such as lower plate  302 , and an upper plate, such as upper plate  310 . As shown in  FIG.  3   , an example cell composition can be an anode plate, such as anode plate  304 , on top of the lower plate  302 , a first separator plate, such as separator plate  306   a  on top of the anode plate  304 , a cathode plate, such as cathode plate  308 , on top of the first separator plate  306   a , and a second separator plate, such as separator plate  306   b , on top of the cathode plate  308 . 
     In at least one embodiment, the method  500  can involve reducing the speed of the pallets  106   a - j  as they approach an assembly station  108   a - e  to receive a battery component. That is, battery components can be loaded to battery stacks while in motion. Alternatively, the pallets  106   a - j  can be brought to a full stop at an assembly station  108   a - e  to receive battery component on the battery stacks at step  504 . 
     In at least one embodiment, the battery components can be received in a specific order in each revolution of the predetermined sequence. For example, the battery components received in one revolution can form a single battery cell. As such, the predetermined sequence for assembling a battery stack can include a plurality of revolutions, the number of revolutions corresponding to the number of cells included in the battery stack. 
     In at least one embodiment, the battery components can be received in a different specific order in each revolution of the predetermined sequence. For example, the battery components required for a single battery cell may require more than one revolution. For example, a first revolution can include a first separator, an anode, and a second separator and a second revolution can include a third separator, a cathode, and a fourth separator. As such, the predetermined sequence for assembling a battery stack can include a plurality of revolutions, the number of revolutions corresponding to twice the number of cells included in the battery stack. 
     In at least one embodiment, the plurality of pallets  106   a - j  can be moved around the track synchronously. That is, each of the plurality of pallets  106   a - j  can be moved amongst the stations  108   a - e ,  110   a - b  at the same time. 
     In at least one embodiment, the plurality of pallets  106   a - j  can be moved around the track asynchronously. That is, a pallet  106   a - j  can be moved from a station at anytime, irrespective of whether other pallets  106   a - j  have been processed by their respective stations. In this manner, once a station has completed processing on a battery stack, the pallet  106   a - j  for the battery stack can be moved to another station. In some cases, there can be a queue at the stations to process unfinished battery stacks. 
     At step  506 , the method  500  can involve unloading, by the at least one transfer station  110   a - b , the plurality of battery stacks from the plurality of pallets  106   a - j . In at least one embodiment, each completed battery stack can be held in a carrier, such as carrier  200 , and unloading the plurality of battery stacks  222  can involve unloading the carriers with the battery stack  222  held therein from the track  202 . In other embodiments, the completed battery stack, such as completed battery stack  222 , can be unloaded from the pallet  106   a - j  without the carrier  200 . 
     Turning now to  FIG.  6   , illustrated therein is a tab bending machine  600  according to another embodiment. In particular, the bending machine  600  may be configured to provide one or more bends to one or more contact tabs of the a battery to ensure that multiple components can be joined together. For example, the bending machine  600  may be used to provide bends to contact tabs of a first cathode and a second cathode such that those contact tabs can be electrically connected together. 
     As shown, in one configuration the bending machine  600  includes an upper jaw  602  and a cooperating lower jaw  604 . During bending, a workpiece  606  (such as the contact tab of a particular anode or cathode) is received between the jaws  602 ,  604 . The jaws  602 ,  604  can then be closed (such as by the operation of an electric motor, using hydraulic pressure, and so on), and the jaws  602 ,  604  are sized and shaped to impart a desired bending shape to the workpiece  606 . This can allow, for example, contact tabs of multiple anodes or cathodes to be more easily electrically connected to each other. 
     For example,  FIG.  7    shows an assembly  700  having two anodes  702 ,  704  according to one embodiment. In particular, the first anode  702  has a first contact tab  706 , while the second anode  704  has a second contact tab  708 . The first tab  706  has been bent to with a first bend profile  710 , while the second tab  708  has been bent with a second bend profile  712  (i.e., using the bending machine  600 ). The bend profiles  710 ,  712  are selected so that when the anodes  702 ,  704  are stacked, their contact tabs  706 ,  708  will have an engaged portion  714  in which the contact tabs  706 ,  708  are in close contact. This can allow the contact tabs  706 ,  708  to be welded together (i.e., at weld  716 ) such as by using a spot welder. At the same time, the bend profiles  710 ,  712  tend to avoid mechanical interference between the contact tabs  706 ,  708 , and may help avoid undesired contact, which could trigger unwanted shorts and the like. 
       FIG.  8    shows a similar schematic of another assembly  800  having two cathodes  802 ,  804  according to another embodiment. As shown the contact tabs  806 ,  808  of the cathodes  802 ,  804  have different bend profiles  810 ,  812  that cooperate to provide an engaged portion  814 , which can be useful for electrically connecting the cathodes  802 , 804 , such as via a weld  816 . 
     Turning now to  FIG.  9   , illustrated therein is a schematic of an assembly  900  having three anodes  902 ,  904 ,  905  according to another embodiment. In general, the assembly  900  is similar to the assemblies  700  and  800  described above, except for the addition of a third anode or cathode. In particular, the anodes  902 ,  904 ,  905  as shown each have a contact tab  906 ,  908 ,  909 , each having a bend profile  910 ,  912 ,  913  which are selected so as to provide for an engaged portion  914  to help ensure good electrical connections between the anodes  902 ,  904 ,  905 . 
     In some versions, one or more of the anodes may have separator plates therebetween, such as the separator plate  920  in between anodes  902 ,  904 . 
       FIG.  10    is a similar assembly  100  except having three cathodes  1002 ,  1004 ,  1005  according to another embodiment. Similar cooperating bends are provided in the contact tabs thereof to ensure good electrical connections can be made. 
     For simplicity and clarity of illustration, elements shown in the drawings have not necessarily been drawn to scale. The dimensions of some of the elements may be exaggerated relative to other elements for clarity. It will be appreciated that for simplicity and clarity of illustration, where considered appropriate, reference numerals may be repeated among the drawings to indicate corresponding or analogous elements or steps. In addition, numerous specific details are set forth in order to provide a thorough understanding of the exemplary embodiments described herein. However, it will be understood by those of ordinary skill in the art that the embodiments described herein may be practiced without these specific details. In other instances, well-known methods, procedures and components have not been described in detail so as not to obscure the embodiments generally described herein. Furthermore, this description is not to be considered as limiting the scope of the embodiments described herein in any way, but rather as merely describing the implementation of various embodiments as described. 
     It should be noted that terms of degree such as “substantially”, “about” and “approximately” when used herein mean a reasonable amount of deviation of the modified term such that the end result is not significantly changed. These terms of degree should be construed as including a deviation of the modified term if this deviation would not negate the meaning of the term it modifies. 
     In addition, as used herein, the wording “and/or” is intended to represent an inclusive-or. That is, “X and/or Y” is intended to mean X or Y or both, for example. As a further example, “X, Y, and/or Z” is intended to mean X or Y or Z or any combination thereof. 
     It should be noted that the term “coupled” used herein indicates that two elements can be directly coupled to one another or coupled to one another through one or more intermediate elements. 
     The embodiments of the systems and methods described herein may be implemented in hardware or software, or a combination of both. These embodiments may be implemented in computer programs executing on programmable computers, each computer including at least one processor, a data storage system (including volatile memory or non-volatile memory or other data storage elements or a combination thereof), and at least one communication interface. 
     For example, and without limitation, the control system (referred to below as computing devices) may be a server, network appliance, embedded device, computer expansion module, a personal computer, laptop, personal data assistant, cellular telephone, smart-phone device, tablet computer, a wireless device or any other computing device capable of being configured to carry out the methods described herein. 
     In some embodiments, the communication interface may be a network communication interface. In embodiments in which elements are combined, the communication interface may be a software communication interface, such as those for inter-process communication (IPC). In still other embodiments, there may be a combination of communication interfaces implemented as hardware, software, and combination thereof. 
     Program code may be applied to input data to perform the functions described herein and to generate output information. The output information is applied to one or more output devices, in known fashion. 
     Each program may be implemented in a high level procedural or object oriented programming and/or scripting language, or both, to communicate with a computer system. However, the programs may be implemented in assembly or machine language, if desired. In any case, the language may be a compiled or interpreted language. Each such computer program may be stored on a storage media or a device (e.g. ROM, magnetic disk, optical disc) readable by a general or special purpose programmable computer, for configuring and operating the computer when the storage media or device is read by the computer to perform the procedures described herein. Embodiments of the system may also be considered to be implemented as a non-transitory computer-readable storage medium, configured with a computer program, where the storage medium so configured causes a computer to operate in a specific and predefined manner to perform the functions described herein. 
     Various embodiments have been described herein by way of example only. Various modification and variations may be made to these example embodiments. Also, in the various user interfaces illustrated in the drawings, it will be understood that the illustrated user interface text and controls are provided as examples only and are not meant to be limiting. Other suitable user interface elements may be possible.