A triaxial flexible stacking system and method for power batteries

Abstract

This invention provides a three-axis flexible stacking system and method for power batteries in the field of large-scale power battery production equipment. The system includes: a gantry; a Y-axis module horizontally positioned at the top of the gantry; an X-axis module horizontally positioned at the moving end of the Y-axis module; a Z-axis module vertically positioned at the moving end of the X-axis module; a gripper positioned at the moving end of the Z-axis module; a camera positioned at the bottom of the gripper; a laser sensor positioned at the bottom of the gripper; a pressure sensor positioned inside the gripper; a cylinder assembly positioned on the gripper; a PLC connected to the Y-axis module, X-axis module, Z-axis module, gripper, camera, laser sensor, pressure sensor, and cylinder assembly; and a display screen connected to the PLC. The advantages of this invention are: significantly improved large-scale power battery stacking capability and accuracy, and significantly reduced stacking costs.

Description

Technical Field

[0001] This invention relates to the field of large-scale power battery production equipment technology, and in particular to a three-axis flexible stacking system and method for power batteries. Background Technology

[0002] With traditional energy sources becoming increasingly depleted and environmental pollution worsening, the global energy structure is rapidly shifting towards renewable energy. New energy passenger cars are gradually replacing traditional gasoline-powered vehicles, while large vehicles such as trucks and buses will also be electrified. The power batteries for large new energy vehicles are several times larger than those for passenger cars, and the production processes are more numerous and complex. Therefore, the assembly lines for large power batteries have higher and more complex technical requirements.

[0003] Automated stacking is a crucial step in power battery assembly. Traditionally, robots are used to stack large power batteries. However, due to the limited working radius and load-bearing capacity of robots, they are unable to complete the task of automated stacking of large power batteries. In addition, robots have disadvantages such as high procurement costs and expensive maintenance costs. Furthermore, because there are multiple production steps before stacking, deviations in the stacking of power batteries are easily caused.

[0004] Therefore, how to provide a triaxial flexible stacking system and method for power batteries to improve the stacking capability and accuracy of large power batteries and reduce stacking costs has become an urgent technical problem to be solved. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide a three-axis flexible stacking system and method for power batteries, thereby improving the stacking capability and accuracy of large power batteries and reducing stacking costs.

[0006] In a first aspect, the present invention provides a three-axis flexible stacking system for power batteries, comprising:

[0007] A gantry frame;

[0008] A Y-axis module is horizontally positioned at the top of the gantry frame;

[0009] An X-axis module is horizontally positioned at the moving end of the Y-axis module;

[0010] A Z-axis module is vertically mounted at the moving end of the X-axis module;

[0011] A gripper is located at the moving end of the Z-axis module;

[0012] A camera is located at the bottom end of the gripper;

[0013] A laser sensor is located at the bottom end of the gripper;

[0014] A pressure sensor is located on the inside of the gripper;

[0015] A cylinder assembly is mounted on the gripper;

[0016] A PLC is connected to the Y-axis module, X-axis module, Z-axis module, gripper, camera, laser sensor, pressure sensor and cylinder assembly respectively;

[0017] A display screen is connected to the PLC.

[0018] Furthermore, the cylinder assembly includes:

[0019] A stacking cylinder is mounted on the gripper and connected to the PLC;

[0020] A bottom-supporting cylinder is mounted on the gripper and connected to the PLC;

[0021] A limit cylinder is mounted on the gripper and connected to the PLC;

[0022] A floating cylinder is mounted on the gripper and connected to the PLC.

[0023] Furthermore, the display screen is a touch display screen.

[0024] Furthermore, it also includes:

[0025] A feeding and positioning mechanism is located below the Y-axis module and connected to the PLC;

[0026] A discharge positioning mechanism is located below the Y-axis module, next to the feed positioning mechanism, and connected to the PLC.

[0027] Furthermore, both the feeding positioning mechanism and the discharging positioning mechanism include:

[0028] Two lifting cylinders, with their power output ends facing upwards, are connected to the PLC;

[0029] Two locating pins are vertically positioned at the power output end of the lifting cylinder;

[0030] Several magnetic sensors are symmetrically arranged above the lifting cylinder and connected to the PLC.

[0031] Secondly, the present invention provides a method for triaxial flexible stacking of power batteries, comprising the following steps:

[0032] Step S10: Place the tray containing the power battery on the feeding positioning mechanism and place the battery box on the discharging positioning mechanism.

[0033] Step S20: Based on the start command issued by the display screen, the PLC drives the lifting cylinder to lift the material tray and inserts the positioning pin into the pin hole of the material tray until the power battery is lifted into place by the magnetic sensor.

[0034] Step S30: The PLC moves the gripper above the power battery through the Y-axis module, X-axis module and Z-axis module, and verifies the position of the power battery through the camera;

[0035] Step S40: The PLC verifies the distance between the gripper and the power battery using a laser sensor;

[0036] In step S50, the PLC uses the Y-axis module, X-axis module and Z-axis module to link the grippers to pick up the power battery and automatically transfer the power battery into the battery box for stacking.

[0037] Further, step S30 specifically includes:

[0038] The PLC moves the grippers above the power battery using the Y-axis, X-axis, and Z-axis modules. It then takes a picture of the power battery using a camera and analyzes the picture using an artificial intelligence algorithm to determine if there is a deviation between the power battery's position and the preset position. If so, the grippers are used to adjust the position of the power battery; otherwise, the process proceeds to step S40.

[0039] Further, step S40 specifically includes:

[0040] The PLC uses a laser sensor to verify the distance between the gripper and the power battery, and determines whether the distance is within the preset height range. If not, the height of the gripper is adjusted through the Z-axis module; if so, the process proceeds to step S50.

[0041] Furthermore, in step S50, during the process of the gripper picking up the power battery, a floating cylinder provides a buffer for the gripper's picking up, a bottoming cylinder supports the power battery from the bottom, a limiting cylinder limits the power battery, and a stacking cylinder senses the stacking state of the power battery.

[0042] The advantages of this invention are:

[0043] By setting up Y-axis, X-axis, and Z-axis modules on the gantry, and having the grippers perform three-axis displacement via these modules, this method offers a larger working radius and load-bearing capacity compared to traditional robot stacking. Furthermore, its hardware and maintenance costs are lower than those of traditional robots, significantly improving the stacking capability of large power batteries and greatly reducing stacking costs. Additionally, by using cameras and laser sensors on the grippers to determine the position and distance of the power batteries, positioning pins to locate the pallets, and magnetic sensors to sense the lifting height of the power batteries, the stacking accuracy of large power batteries is greatly improved. Attached Figure Description

[0044] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0045] Figure 1 This is a front view of a three-axis flexible stacking system for power batteries according to the present invention.

[0046] Figure 2 This is a side view of a three-axis flexible stacking system for power batteries according to the present invention.

[0047] Figure 3 This is a top view of a three-axis flexible stacking system for power batteries according to the present invention.

[0048] Figure 4 This is a circuit block diagram of a three-axis flexible stacking system for power batteries according to the present invention.

[0049] Figure 5 This is a flowchart of a three-axis flexible stacking method for power batteries according to the present invention.

[0050] Marker explanation:

[0051] 100-A three-axis flexible stacking system for power batteries, 1-Gantry, 2-Y-axis module, 3-X-axis module, 4-Z-axis module, 5-Gripper, 6-Camera, 7-Laser sensor, 8-Pressure sensor, 9-Cylinder assembly, 10-PLC, 11-Display screen, 12-Feeding positioning mechanism, 13-Discharge positioning mechanism, 91-Stacking cylinder, 92-Bottoming cylinder, 93-Limiting cylinder, 94-Floating cylinder, 121-Lifting cylinder, 122-Positioning pin, 123-Magnetic sensor. Detailed Implementation

[0052] The overall concept of the technical solution in this application embodiment is as follows: A Y-axis module, an X-axis module, and a Z-axis module are set on the gantry. The gripper performs three-axis displacement through the Y-axis module, X-axis module, and Z-axis module to replace the traditional robot, thereby improving the stacking capability of large power batteries and reducing stacking costs. By setting cameras and laser sensors on the gripper to determine the position and distance of the power batteries, setting positioning pins to position the material tray, and setting magnetic sensors to sense the lifting height of the power batteries, the stacking accuracy of large power batteries is improved.

[0053] Please refer to Figures 1 to 5 As shown, a preferred embodiment of the triaxial flexible stacking system 100 for power batteries of the present invention includes:

[0054] A gantry frame 1 is used to support the triaxial flexible stacking system 100;

[0055] A Y-axis module 2 is horizontally positioned at the top of the gantry frame 1 and is used for the Y-axis displacement of the gripper 5;

[0056] An X-axis module 3 is horizontally positioned at the moving end of the Y-axis module 2 and is used for the X-axis displacement of the gripper 5;

[0057] A Z-axis module 4 is vertically disposed at the moving end of the X-axis module 3 and is used for the Z-axis displacement of the gripper 5;

[0058] A gripper 5 is located at the moving end of the Z-axis module 4 and is used to transfer stacked power batteries (not shown).

[0059] A camera 6 is located at the bottom of the gripper 5 and is used to take pictures of the power battery in order to determine whether the power battery is placed in the correct position.

[0060] A laser sensor 7 is located at the bottom of the gripper 5 to sense the distance between the gripper 5 and the power battery.

[0061] A pressure sensor 8 is located inside the gripper 5 to prevent overvoltage of the power battery;

[0062] A cylinder assembly 9 is mounted on the gripper 5;

[0063] A PLC 10 is connected to the Y-axis module 2, X-axis module 3, Z-axis module 4, gripper 5, camera 6, laser sensor 7, pressure sensor 8, and cylinder group 9 respectively, and is used to control the operation of the stacking system 100. In specific implementation, any PLC that can perform this function can be selected from the existing technology, and there is no limitation on the model. Moreover, the control program is well known to those skilled in the art, and it can be obtained by those skilled in the art without creative effort.

[0064] A display screen 11 is connected to the PLC 10 and is used to send operation commands to the PLC 10 and display the operating data of the stacking system 100.

[0065] The cylinder assembly 9 includes:

[0066] A stacking cylinder 91 is mounted on the gripper 5 and connected to the PLC 10. It senses the stacking status of the power battery, i.e. it extends out before stacking and is pressed back to the initial position by the battery box (not shown) during the stacking process, indicating that the stacking is complete.

[0067] A bottom-supporting cylinder 92 is mounted on the gripper 5 and connected to the PLC 10, and is used to support the power battery from the bottom.

[0068] A limiting cylinder 93 is mounted on the gripper 5 and connected to the PLC 10, and is used to limit the power battery.

[0069] A floating cylinder 94 is mounted on the gripper 5 and connected to the PLC 10 to make the gripper 5 flexible, that is, to provide a buffer for the gripper 5 to grasp.

[0070] The display screen 11 is a touch display screen.

[0071] Also includes:

[0072] A feeding and positioning mechanism 12 is located below the Y-axis module 2 and is connected to the PLC 10;

[0073] A discharge positioning mechanism 13 is located below the Y-axis module 2, next to the feed positioning mechanism 12, and connected to the PLC 10.

[0074] Both the feeding positioning mechanism 12 and the discharging positioning mechanism 13 include:

[0075] Two lifting cylinders 121, with their power output ends facing upwards, are connected to the PLC 10;

[0076] Two positioning pins 122 are vertically mounted on the power output end of the lifting cylinder 121 and are used to position the material tray (not shown).

[0077] Several magnetic sensors 123 are symmetrically arranged above the lifting cylinder 121 and connected to the PLC 10 to sense the lifting height of the power battery.

[0078] A preferred embodiment of the present invention provides a method for the triaxial flexible stacking of power batteries, comprising the following steps:

[0079] Step S10: Place the tray containing the power battery on the feeding positioning mechanism and place the battery box on the discharging positioning mechanism.

[0080] Step S20: Based on the start command issued by the display screen, the PLC drives the lifting cylinder to lift the material tray and inserts the positioning pin into the pin hole of the material tray until the power battery is lifted into place by the magnetic sensor.

[0081] Step S30: The PLC moves the gripper above the power battery through the Y-axis module, X-axis module and Z-axis module, and verifies the position of the power battery through the camera;

[0082] Step S40: The PLC verifies the distance between the gripper and the power battery using a laser sensor;

[0083] In step S50, the PLC uses the Y-axis module, X-axis module and Z-axis module to link the grippers to pick up the power battery and automatically transfer the power battery into the battery box for stacking.

[0084] Step S30 specifically involves:

[0085] The PLC moves the grippers above the power battery using the Y-axis, X-axis, and Z-axis modules. It then takes a picture of the power battery using a camera and analyzes the picture using an artificial intelligence algorithm to determine if there is a deviation between the power battery's position and the preset position. If so, the grippers are used to adjust the position of the power battery; otherwise, the process proceeds to step S40.

[0086] Step S40 specifically involves:

[0087] The PLC uses a laser sensor to verify the distance between the gripper and the power battery, and determines whether the distance is within the preset height range. If not, the height of the gripper is adjusted through the Z-axis module; if so, the process proceeds to step S50.

[0088] In step S50, during the process of the gripper picking up the power battery, a floating cylinder provides a buffer for the gripper, a bottoming cylinder supports the power battery, a limiting cylinder limits the power battery, and a stacking cylinder senses the stacking state of the power battery.

[0089] In summary, the advantages of this invention are:

[0090] By setting up Y-axis, X-axis, and Z-axis modules on the gantry, and having the grippers perform three-axis displacement via these modules, this method offers a larger working radius and load-bearing capacity compared to traditional robot stacking. Furthermore, its hardware and maintenance costs are lower than those of traditional robots, significantly improving the stacking capability of large power batteries and greatly reducing stacking costs. Additionally, by using cameras and laser sensors on the grippers to determine the position and distance of the power batteries, positioning pins to locate the pallets, and magnetic sensors to sense the lifting height of the power batteries, the stacking accuracy of large power batteries is greatly improved.

[0091] While specific embodiments of the present invention have been described above, those skilled in the art should understand that the specific embodiments described are merely illustrative and not intended to limit the scope of the present invention. Equivalent modifications and variations made by those skilled in the art in accordance with the spirit of the present invention should be covered within the scope of protection of the claims of the present invention.

Claims

1. A triaxial flexible stacking system for power batteries, characterized in that: include: A gantry frame; A Y-axis module is horizontally positioned at the top of the gantry frame; An X-axis module is horizontally positioned at the moving end of the Y-axis module; A Z-axis module is vertically mounted at the moving end of the X-axis module; A gripper is located at the moving end of the Z-axis module; A camera is located at the bottom end of the gripper; A laser sensor is located at the bottom end of the gripper; A pressure sensor is located on the inside of the gripper; A cylinder assembly is mounted on the gripper; A PLC is connected to the Y-axis module, X-axis module, Z-axis module, gripper, camera, laser sensor, pressure sensor and cylinder assembly respectively; A display screen is connected to the PLC; The cylinder assembly includes: A stacking cylinder is mounted on the gripper and connected to the PLC. It is used to sense the stacking status of the power batteries. It extends before stacking and is pressed back to the initial position by the battery box during the stacking process, indicating that the stacking is complete. A bottom-supporting cylinder is mounted on the gripper and connected to the PLC for supporting the power battery. A limit cylinder is mounted on the gripper and connected to the PLC for limiting the position of the power battery; A floating cylinder is mounted on the gripper and connected to the PLC to make the gripper flexible, providing a buffer for the gripper's gripping action.

2. The power battery triaxial flexible stacking system as described in claim 1, characterized in that: The display screen is a touch screen.

3. The power battery triaxial flexible stacking system as described in claim 1, characterized in that: Also includes: A feeding and positioning mechanism is located below the Y-axis module and connected to the PLC; A discharge positioning mechanism is located below the Y-axis module, next to the feed positioning mechanism, and connected to the PLC.

4. The power battery triaxial flexible stacking system as described in claim 3, characterized in that: Both the feeding positioning mechanism and the discharging positioning mechanism include: Two lifting cylinders, with their power output ends facing upwards, are connected to the PLC; Two locating pins are vertically positioned at the power output end of the lifting cylinder; Several magnetic sensors are symmetrically arranged above the lifting cylinder and connected to the PLC.

5. A method for triaxial flexible stacking of power batteries, characterized in that: The method requires the use of the stacking system as described in any one of claims 1 to 4, and includes the following steps: Step S10: Place the tray containing the power battery on the feeding positioning mechanism and place the battery box on the discharging positioning mechanism. Step S20: Based on the start command issued by the display screen, the PLC drives the lifting cylinder to lift the material tray and inserts the positioning pin into the pin hole of the material tray until the power battery is lifted into place by the magnetic sensor. Step S30: The PLC moves the gripper above the power battery through the Y-axis module, X-axis module and Z-axis module, and verifies the position of the power battery through the camera; Step S40: The PLC verifies the distance between the gripper and the power battery using a laser sensor; In step S50, the PLC uses the Y-axis module, X-axis module and Z-axis module to link the grippers to pick up the power battery and automatically transfer the power battery into the battery box for stacking. During the process of gripping the power battery, a floating cylinder provides cushioning for the gripper, a bottoming cylinder supports the power battery from the bottom, a limiting cylinder limits the power battery, and a stacking cylinder senses the stacking status of the power battery.

6. The method for triaxial flexible stacking of power batteries as described in claim 5, characterized in that: Step S30 specifically involves: The PLC moves the grippers above the power battery using the Y-axis, X-axis, and Z-axis modules. It then takes a picture of the power battery using a camera and analyzes the picture using an artificial intelligence algorithm to determine if there is a deviation between the power battery's position and the preset position. If so, the grippers are used to adjust the position of the power battery; otherwise, the process proceeds to step S40.

7. The method for triaxial flexible stacking of power batteries as described in claim 5, characterized in that: Step S40 specifically involves: The PLC uses a laser sensor to verify the distance between the gripper and the power battery, and determines whether the distance is within the preset height range. If not, the height of the gripper is adjusted through the Z-axis module; if so, the process proceeds to step S50.

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