A processing platform and control method based on the metal shell of a battery pack

Abstract

The present application relates to a processing platform and control method based on the metal shell of a battery pack. The equipment includes a controlled lifting end and an adjusting mechanism to perform dynamic adjustments based on the collected position information. The clamping and positioning mechanism can firmly fix the battery pack accessories on the material placement plane of the assembly platform. In addition, a transmitting unit that cooperates with the sensor component is provided at the docking interface to monitor the position of the docking interface in real time. Moreover, the controller can further accurately control the movement of the lifting end and the adjusting end based on the position information collected by the sensor component, so that the assembly platform is adjusted to the target posture, ensuring automatic and accurate alignment of the fixing hole and the docking interface. Through the above technical solution, the transfer equipment effectively solves the problems of low operating efficiency, high labor intensity, and alignment accuracy being greatly affected by human factors when manually aligning the docking interface and the fixing hole in the prior art, thereby realizing efficient automation of assembly operations and reducing the labor intensity of operators.

Description

Technical Field

[0001] The present invention relates to processing equipment, and in particular to a processing platform and a control method based on a metal shell of a battery pack. Background Art

[0002] With the rapid development of the new energy vehicle industry, battery packs, as an important component of new energy vehicles, have increasingly higher requirements for the assembly accuracy and efficiency of their accessories.

[0003] Existing assembly auxiliary equipment mostly takes the form of a cart with a material placement surface, and usually has basic material placement and flat load-bearing functions for placing parts to be assembled. This type of cart provides a stable operating platform for the transportation and processing of parts.

[0004] However, this existing assembly assistance equipment has certain limitations when assembling battery pack components. During the assembly process of components such as automotive battery pack crossbars and brackets, operators must manually align docking interfaces (e.g., docking interfaces, the muzzle of an electric screwdriver, etc.) with the fixing holes on the components to complete the connection. However, due to the large size of battery pack components and the diverse distribution of fixing holes, manual assembly often suffers from low efficiency and high labor intensity, resulting in low assembly efficiency. Therefore, a processing platform and control method based on the metal shell of the battery pack are urgently needed to solve these problems. Summary of the Invention

[0005] The purpose of the present invention is to provide a processing platform based on the metal shell of the battery pack, which can realize automatic and precise alignment of the docking interface and the fixing holes of the battery pack accessories, so as to improve the efficiency and quality of the assembly operation and reduce the labor intensity of the operator.

[0006] The technical solution adopted by the present invention to solve the above problems is: a processing platform based on the metal shell of the battery pack, comprising:

[0007] The assembly platform includes a material placement surface for placing battery pack accessories;

[0008] A clamping and positioning mechanism connected to the assembly platform to controllably restrict the battery pack assembly to a target position on the loading plane;

[0009] a base, the base including a controlled lifting end;

[0010] An adjusting mechanism is provided at the lifting end, the adjusting mechanism comprising an adjusting end with controlled movement, the adjusting end being connected to the assembly platform;

[0011] A transmitting unit is arranged at the docking interface;

[0012] Testing agencies, including:

[0013] A travel component connected to the assembly platform, the travel component comprising a first moving end that moves in a controlled manner, wherein a moving track of the first moving end is parallel to the material placement plane;

[0014] A lifting assembly connected to the first moving end, the lifting assembly including a second moving end that moves in a controlled manner, wherein a moving trajectory of the second moving end is perpendicular to the material loading plane;

[0015] a base plate connected to the second movable end, the base plate including an assembly slot extending therethrough, the assembly slot being configured to be coaxially arranged with a fixing hole of the battery pack accessory on the loading plane during processing of the battery pack accessory;

[0016] A sensor assembly is provided on the substrate, the sensor assembly is provided around the assembly groove to form a monitoring area, and the sensor assembly is configured to continuously collect position information of the transmitting unit when the transmitting unit enters the monitoring area;

[0017] A controller is connected to the base, the adjustment mechanism and the detection mechanism, and the controller is configured to receive the position information and control the movement of the lifting end and the adjustment end according to the position information so that the fixing hole of the battery pack accessory on the material placement plane is aligned with the docking port.

[0018] Preferably, the transmitting unit is a magnet or a controlled electromagnet.

[0019] Preferably, the sensing component is a magnetic sensing array, which includes a plurality of magnetic sensors. The magnetic sensors are arranged in a two-dimensional array, and the center of the two-dimensional array coincides with the center of the assembly slot.

[0020] Preferably, the two-dimensional array is a rectangular array, and the distances between any two adjacent magnetic sensors are equal.

[0021] Preferably, the magnetic sensor is a three-axis magnetic sensor.

[0022] Preferably, a magnetic shielding layer is provided in the substrate.

[0023] Preferably, the adjustment mechanism comprises:

[0024] A six-degree-of-freedom platform, connected to the controller, comprising:

[0025] a first mounting seat connected to the lifting end;

[0026] a second mounting seat, the second mounting seat being the adjustment end, and the second mounting seat being connected to a side of the assembly platform facing away from the material placement plane;

[0027] a servo screw assembly, disposed between the first mounting seat and the second mounting seat, for adjusting the relative posture of the assembly platform in a controlled manner;

[0028] A plurality of elastic support members are provided between the assembly platform and the lifting end, and the elastic supports are arranged at equal intervals around the edge of the bottom of the assembly platform.

[0029] Preferably, the transmitting unit is a magnet or an electromagnet.

[0030] The sensing component is a magnetic sensing array, which includes a plurality of three-axis magnetic sensors. The three-axis magnetic sensors are arranged in a rectangular two-dimensional array, the spacing between each two adjacent magnetic sensors is equal, and the center of the two-dimensional array coincides with the center of the assembly slot.

[0031] A magnetic shielding layer is provided in the substrate.

[0032] In particular, a control method for the above-mentioned transfer equipment includes:

[0033] Obtaining size parameters of the battery pack accessory and target position parameters of the center point of the fixing hole of the battery pack accessory in space when the battery pack accessory is fixed on the material placement plane by the clamping and positioning mechanism;

[0034] Acquiring real-time detection data of each of the three-axis magnetic sensors in the magnetic sensor array provided in the detection mechanism of the transfer device, the real-time detection data including magnetic flux density values in each axial direction at the position corresponding to the three-axis magnetic sensor;

[0035] Determine whether the real-time detection data of all the three-axis magnetic sensors in the magnetic sensor array meets a target matching condition, where the target matching condition includes:

[0036] The distribution of the magnetic flux density values of all the three-axis magnetic sensors satisfies a symmetry judgment condition, or;

[0037] The distance between the real-time spatial position of the transmitting unit calculated based on the magnetic flux density values of all the three-axis magnetic sensors and the spatial position of the center point of the target fixing hole on the battery pack assembly is less than a preset tolerance threshold;

[0038] If the real-time detection data of all the three-axis magnetic sensors in the magnetic sensor array meet the target matching condition, the adjustment end of the adjustment mechanism is controlled to stop moving so that the target fixing hole on the battery pack accessory is coaxial with the docking interface space.

[0039] Preferably, the symmetry judgment condition includes:

[0040] The standard deviation of the output values of the three-axis magnetic sensors in the magnetic sensor array is less than a set threshold, or;

[0041] The difference between the maximum value and the minimum value of the output value is less than a preset value;

[0042] The preset tolerance threshold should be within 0.3 mm.

[0043] Beneficial effects of the embodiments of the present invention:

[0044] 1. Since the present application adopts the cooperation of the lifting end and the adjustment mechanism of the base, the transmitting unit and the detection mechanism are used to collect the position information of the docking interface in real time, and the movement of the lifting end and the adjustment end is precisely controlled by the controller, so that the fixing hole of the battery pack accessory on the assembly platform is automatically and accurately aligned with the docking interface. Therefore, it effectively solves the problems of low working efficiency and high labor intensity when manually aligning the docking interface and the fixing hole in the existing technology, thereby achieving a significant improvement in the processing efficiency of the battery pack accessories, a significant reduction in labor intensity, and stable and reliable assembly quality.

[0045] 2. Due to the use of a magnetic sensor array to collect the position information of the docking interface in real time, the spatial position deviation between the docking interface and the fixing hole of the battery pack accessory is accurately calculated, and the posture of the material placement platform is adjusted in real time according to the position deviation, so that the fixing hole of the battery pack accessory automatically moves toward the docking interface until the real-time detection data reaches a fixed value. This effectively solves the problems of poor manual alignment accuracy, low efficiency and high labor intensity in the existing technology, and thus realizes the automation and high-precision alignment of the assembly operation, improves the assembly operation efficiency and ensures the stability and reliability of the assembly quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0046] Figure 1 A schematic structural diagram of a processing platform based on a metal shell of a battery pack proposed in one embodiment of the present invention is shown.

[0047] Figure 2 Shown Figure 1 Enlarged view of point A in the middle.

[0048] Figure 3 A schematic structural diagram showing an assembly platform and an adjustment mechanism in a connected state in one embodiment of the present invention is shown.

[0049] Figure 4 A schematic structural diagram of a six-degree-of-freedom platform in one embodiment of the present invention is shown.

[0050] Figure 5 A schematic flow chart of a control method for controlling a transfer device proposed in one embodiment of the present invention is shown.

[0051] Among them: 10, base; 110, lifting end; 20, assembly platform; 210, material placement plane; 30, clamping and positioning mechanism; 40, adjustment mechanism; 410, six-degree-of-freedom platform; 411, first mounting seat; 412, second mounting seat; 413, servo screw assembly; 420, elastic support member; 50, detection mechanism; 510, stroke assembly; 520, lifting assembly; 530, substrate; 531, assembly slot; 540, sensor assembly. DETAILED DESCRIPTION

[0052] The following embodiments of the present invention are described in further detail with reference to the accompanying drawings and examples. The following examples are used to illustrate the present invention but are not intended to limit the scope of the present invention.

[0053] In the description of the present application, it should be understood that the terms "center", "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside" and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the scope of protection of the present application. In addition, the terms "first", "second", etc. are only used for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, features defined as "first", "second", etc. may explicitly or implicitly include one or more of the features. In the description created by the present application, unless otherwise specified, "multiple" means two or more.

[0054] In the description of this application, it should be noted that, unless otherwise expressly specified or limited, the terms "mounted," "connected," and "connected" should be understood in a broad sense. For example, they can refer to fixed connections, detachable connections, or integral connections; mechanical connections or electrical connections; direct connections or indirect connections through an intermediate medium; and internal connections between two components. Those skilled in the art will understand the specific meanings of the above terms in this application based on specific circumstances.

[0055] See also Figures 1 to 3In a preferred embodiment of the present application, a processing platform is proposed. This processing equipment is used for assembling battery pack components and provides a movable assembly station for the assembly of battery pack components. The processing platform includes an assembly platform 20, a clamping and positioning mechanism 30, and a base 10. The assembly platform 20 includes a material placement plane 210 for placing battery pack components. The clamping and positioning mechanism 30 is connected to the assembly platform 20 to controllably restrict the battery pack components to a target position on the material placement plane 210.

[0056] Specifically:

[0057] The assembly platform 20 provides a placement platform for the battery pack accessories, which can be embodied as a flat plate in a specific manner. The shape of the flat plate should be adapted to the battery pack accessories so that the material placement plane 210 has sufficient bearing area. Taking a rectangular flat plate as an example, Figure 1 As shown, the rectangular flat plate consists of two parallel planes, defined by their length and width, forming the top and bottom surfaces, respectively. The top surface serves as the loading surface 210, and the center point of loading surface 210 serves as the origin of the spatial coordinate system. The assembly platform 20 can be made of high-strength metal sheet, which offers wear and corrosion resistance. In some embodiments, loading surface 210 can be designed as a modular structure (not shown) to facilitate adjustment or expansion based on the size of different battery pack components.

[0058] The clamping and positioning mechanism 30, through its tight connection with the assembly platform 20, stably secures the battery pack assembly, thereby confining it to a target position on the loading surface 210 of the assembly platform 20. This target position is determined by the clamping and positioning mechanism 30, whose design must be adapted to the battery pack assembly being transported. Once the target position is determined, the spatial coordinates of the center points of the fixing holes on the battery pack assembly that are confined there are also determined.

[0059] Specifically, the clamping mechanism can be embodied as multiple symmetrically arranged claws, springs, or cylinder-type clamping units that move in a coordinated manner along a predetermined trajectory, thereby applying uniform pressure to the battery pack during operation. In some embodiments, the clamping and positioning mechanism 30 is connected to a sensor (such as a displacement sensor, a pressure sensor) and an actuator (such as a servo motor or a cylinder) to monitor the clamping status in real time and automatically adjust the clamping force based on preset parameters (pressure, angle, etc.) to ensure that parts do not shift during transportation and assembly. Moreover, to accommodate batch operations on the production line, the clamping and positioning mechanism 30 can also be designed with a quick lock / release structure, allowing for rapid switching between different working stages (loading, processing, and unloading).

[0060] The base 10 serves as the basic support platform for the transfer equipment. Specifically, it is a hollow frame structure formed by splicing profiles. The frame is typically a rectangular parallelepiped, with the assembly platform 20 positioned atop it. To enable flexible movement or fixation of the equipment within the production line, the bottom of the frame can be equipped with casters or rails that interface with workshop fixtures. Furthermore, because the base 10 is a hollow frame, it accommodates numerous wire ducts and cable conduits for transmitting signals from the various actuators and control systems, ensuring stable communication and electrical safety for the entire system.

[0061] Prior art auxiliary assembly equipment used for transferring battery pack components has limitations when assembling battery pack components. In particular, during the assembly of components such as automotive battery pack crossbars and brackets, operators must manually align docking ports (which can be docking holes or the blade of a screwdriver) with the mounting holes on the components to complete assembly. However, due to the large size of battery pack components and the diverse location of mounting holes, manual assembly often results in low efficiency and high labor intensity, resulting in inefficient assembly.

[0062] Unlike the prior art, the base 10 of the transfer device also includes a controlled lifting end 110, and the transfer device also includes an adjustment mechanism 40, a launch unit, a detection mechanism 50, and a controller. The adjustment mechanism 40 is located at the lifting end 110 and includes a controlled movement adjustment end connected to the assembly platform 20. The launch unit is located at the docking port. The detection mechanism 50 includes a stroke component 510, a lifting component 520, a substrate 530 and a sensor component 540; wherein, the stroke component 510 is connected to the assembly platform 20, and the stroke component includes a first moving end for controlled movement, and the moving trajectory of the first moving end is parallel to the material loading plane 210; the lifting component 520 is connected to the first moving end, and the lifting component 520 includes a second moving end for controlled movement, and the moving trajectory of the second moving end is perpendicular to the material loading plane 210; the substrate 530 is connected to the second moving end, and the substrate 530 includes an assembly groove 531 set through, and the assembly groove 531 is configured to be coaxially arranged with the fixing hole of the battery pack accessory on the material loading plane 210 during the processing of the battery pack accessory; the sensor component 540 is arranged on the substrate 530, and the sensor component 540 is arranged on the peripheral side of the assembly groove 531 to form a monitoring area, and the sensor component 540 is configured to continuously collect the position information of the transmitting unit when the transmitting unit enters the monitoring area. The controller is connected to the base 10, the adjustment mechanism 40 and the detection mechanism 50, and the controller is configured to receive the position information and control the movement of the lifting end 110 and the adjustment end according to the position information, so that the fixing hole of the battery pack accessory on the material placement plane 210 is aligned with the docking port. In summary, by cooperating with the lifting end 110 of the base 10 and the adjustment mechanism 40, the position information of the docking port is collected in real time by utilizing the transmitting unit and the detection mechanism 50, and the movement of the lifting end 110 and the adjustment end is precisely controlled by the controller, so that the fixing hole of the battery pack accessory on the assembly platform 20 is automatically and precisely aligned with the docking port, thereby effectively solving the problems of low working efficiency and high labor intensity when manually aligning the docking port and the fixing hole in the prior art, thereby achieving a significant improvement in the processing efficiency of the battery pack accessories, a significant reduction in labor intensity, and stable and reliable assembly quality.

[0063] Specifically:

[0064] The base 10 incorporates a controlled lift 110. Specifically, this lift 110 can be implemented as a hydraulic, electric, or servo-driven system to enable fine vertical adjustment of the assembly platform 20. This lift 110 establishes a controllable height adjustment mechanism between the assembly platform 20 and the screwdriver or docking port, thus providing a foundation for subsequent alignment. It should be noted that the lift range of this lift 110 is significantly greater than the vertical (Z-axis) range of motion of the six-degree-of-freedom platform 410, described later.

[0065] The purpose of the adjustment mechanism 40 is to adjust the relative posture of the assembly platform 20 to ensure that the pre-positioning of the battery pack accessories on the material plane 210 can meet the alignment requirements, that is, the axis of the fixing hole of the battery pack accessories constrained on the material plane 210 can be coaxially aligned with the interface. In addition, the adjustment end can be fine-tuned within the predetermined trajectory to implement real-time correction in conjunction with the position information collected by the detection mechanism 50. In one embodiment, Figure 3 As shown, the adjustment mechanism 40 includes a six-degree-of-freedom platform 410, which is connected to and controlled by a controller and includes a first mounting seat 411, a second mounting seat 412, and a servo screw assembly 413. The first mounting seat 411 is connected to the lifting end 110; the second mounting seat 412 serves as the adjustment end and is connected to the side of the assembly platform 20 facing away from the material placement plane 210; and the servo screw assembly 413 is disposed between the first mounting seat 411 and the second mounting seat 412 to controllably adjust the relative posture of the assembly platform 20. It should be noted that the six-degree-of-freedom platform 410 is conventional technology and therefore requires no further explanation.

[0066] The firing unit is mounted on the docking port and utilizes a precision positioning unit that correlates the docking port's movements with the data collected by the detection mechanism 50. The firing unit provides real-time feedback on the muzzle position via a built-in position sensor, providing data input for subsequent control. It should be noted that the relative positional relationship between the docking port's center and the firing unit is a known quantity. Specifically, when the docking port's center is set as the relative origin, the firing unit's spatial coordinates within this coordinate system are known. This facilitates the elimination of deviations caused by the positional difference between the firing unit and the docking port's center in subsequent control methods.

[0067] The base plate 530 is directly connected to the second movable end and is provided with a mounting slot 531. The mounting slot 531 is structurally designed to be coaxial with the fixing holes on the battery pack accessories to achieve the determination of the workpiece hole position.

[0068] The sensor assembly 540 is arranged on the base plate 530, mainly installed around the assembly slot 531, thus forming a complete monitoring area. When the transmitting unit enters this monitoring area, the sensor assembly 540 continuously collects the position information of the docking port to ensure the real-time and accuracy of the data.

[0069] The stroke assembly 510 is used to move the substrate 530 parallel to the loading plane 210, while the lifting assembly 520 is used to move the substrate 530 perpendicular to the loading plane 210. In a preferred embodiment, the stroke assembly 510 can be implemented as a linear slide in conjunction with a lead screw and a servo motor. It is fixed to the base 10 and drives the lifting assembly 520 parallel to the loading plane 210, thereby positioning the substrate 530 within the XY plane (parallel to the loading plane 210). The lifting assembly 520 can be implemented as a Z-axis (perpendicular to the loading plane 210) electric slide or a servo-driven lead screw structure, mounted on the first movable end of the stroke assembly 510. It drives the substrate 530 up and down perpendicular to the loading plane 210 to achieve high-level alignment at the assembly position. The coordinated action of the stroke assembly 510 and the lifting assembly 520 aligns the assembly slot 531 on the substrate 530 with the mounting hole on the battery pack assembly to be assembled. It should be noted that the travel assembly 510 cooperates with the lifting assembly 520 to be suitable for battery pack accessories whose fixing holes are opened on a plane, and when placed on the loading plane 210, the plane is parallel or perpendicular to the loading plane 210.

[0070] It should be further explained that the cooperation between the travel assembly 510 and the lifting assembly 520 is applicable to a variety of fixing hole arrangements, especially when the fixing holes are opened on different planes of the battery pack accessories. Take a typical structure as an example:

[0071] In some battery pack accessories (such as battery pack side frames, crossbeams, or reinforcement plates), fixing holes are often arranged on the plane of the component. For example, the fixing holes are opened on the surface of the outer plate parallel to the battery pack installation direction. When the battery pack accessory is placed on the loading plane 210, the plane where the fixing holes are located is usually parallel to the loading plane 210. At this time, the stroke component 510 drives the base plate 530 to move in the XY plane to achieve precise alignment of the fixing holes and the docking interface in the horizontal plane; the lifting component 520 is used to fine-tune the height of the assembly slot 531 to ensure that the muzzle and the fixing holes are coaxial in the vertical direction. Alternatively, the fixing holes are opened on the end cover of the accessory, which is a structural component perpendicular to the main bearing surface. When the accessory is placed on the loading plane 210, the plane where the fixing holes are located is usually perpendicular to the loading plane 210. At this time, the clamping and positioning mechanism 30 of the assembly platform 20 positions the battery pack accessory in a state where the vertical surface is facing the detection mechanism 50. The lifting component 520 can drive the base plate 530 to move along the Z axis to achieve vertical adjustment of fixing holes at different heights. At the same time, the stroke component 510 ensures that the assembly slot 531 can move in the horizontal direction (such as the Y axis), so that the muzzle scans along the vertical surface of the accessory and is finally positioned above the target fixing hole, thereby completing precise alignment.

[0072] In summary, in the assembly process of the battery pack bracket, it is often necessary to position the multiple fixing holes opened on the side of the frame one by one. In this application, the stroke component 510 and the lifting component 520 form a three-dimensional adjustable platform, which drives the assembly slot 531 on the base plate 530 to be precisely adjusted horizontally and vertically to ensure coordination with the real-time position of the launch unit, so that each fixing hole can achieve high-precision automatic alignment. It should be noted that when assembling the fixing holes on the battery pack accessories, each fixing hole can be numbered in sequence, and the position information of the fixing holes corresponding to the numbers can be input into the controller. Then, the assembly is carried out in sequence according to the size of the number sequence. Under the action of the controller, the stroke component 510 and the lifting component 520 will align the assembly holes on the base plate 530 with the fixing holes in sequence according to the pre-set number sequence, thereby limiting the assembly sequence of the operator.

[0073] The controller is connected to the base 10, adjustment mechanism 40, and detection mechanism 50 via a bus or fieldbus. It integrates a data processing module, a feedback control module, and a communication interface. Based on real-time position information collected by the detection mechanism 50, the controller uses a preset control algorithm to coordinate the movement of the lift end 110 and the adjustment end, ensuring that the mounting holes of the battery pack components on the assembly platform 20 are always precisely aligned with the docking ports. In one specific embodiment, the controller can utilize a Siemens S7-1215C series PLC, which is equipped with multiple digital input and output ports, analog input ports, and an Ethernet communication interface. The controller establishes a high-speed data channel with the adjustment mechanism 40, lift end 110, and sensor assembly 540 via an EtherCAT or PROFINET bus. It uses integrated PID control instructions to achieve precise position control of the adjustment end and lift end 110. The controller receives position information input from the sensor assembly 540 and calculates the deviation between the docking port and the battery pack component mounting hole in real time. It then outputs precise control instructions to the adjustment mechanism 40, achieving automatic alignment of the assembly position. In addition, the controller can be connected to a touch screen HMI to support graphical monitoring and parameter setting of information such as the motion status of each axis, position information, and alarm logs.

[0074] Before the assembly tool is put into operation, the operator first places the battery pack component on the loading surface 210 of the assembly platform 20 of the transfer equipment and initially secures it using the clamping and positioning mechanism 30. This mechanism provides flexible positioning and multi-point clamping based on the component's shape, ensuring that the fixing holes remain stable near the preset target position, providing a foundation for subsequent automatic calibration.

[0075] The docking port is equipped with a transmitter unit, which incorporates a precision position sensor. When activated, the transmitter unit enters the monitoring area defined by the detection mechanism 50, and the sensor assembly 540 collects real-time position data from the transmitter unit. Because the positional relationship between the docking port center and the transmitter unit is a fixed, known quantity, the controller can use this information to infer the spatial coordinates of the actual working end of the docking port.

[0076] The controller is the core control unit of the entire alignment process, which integrates the data acquisition module, feedback control module, position calculation module and motion control module.

[0077] During the data collection and processing process, the controller receives real-time position information from the sensor assembly 540 and calculates the current position of the docking interface in the three-dimensional coordinate system based on the fixed offset between the docking interface and the transmitting unit.

[0078] The controller first controls the lifting end 110 to drive the assembly platform 20 to perform a coarse adjustment along the Z axis to ensure that the assembly platform 20 enters the adjustable range of the six-degree-of-freedom platform 410.

[0079] The controller then uses the six-degree-of-freedom adjustment mechanism 40 to achieve precise posture adjustment, aiming to achieve complete spatial coaxiality between the central axis of the mounting hole on the accessory and the axis of the docking port. This adjustment process is based on closed-loop control logic, using commonly used algorithms such as PID control or adaptive coordinate correction algorithms.

[0080] In practice, the fixing holes on each accessory are numbered (e.g., A1, A2, ..., An), and their corresponding spatial coordinates are pre-entered into the controller. The controller then controls the coordinated movement of the travel assembly 510 and the lift assembly 520 in sequence, aligning the assembly slots 531 on the base plate 530 with the numbered holes. This sequential control not only ensures a controllable assembly sequence but also avoids manual errors, improving overall operational efficiency and consistency.

[0081] When the controller determines that the current fixing hole and the muzzle are within an acceptable tolerance (e.g., less than ±0.3mm), the system issues an assembly start command. The assembly process is monitored in real time. If any micro-displacement of the assembly platform 20 (e.g., due to vibration) is detected during the process, the controller immediately issues a subtle correction command, dynamically compensating via the 6-DOF platform 410 to ensure precise coaxiality throughout the assembly process.

[0082] Once assembly is complete, the controller instructs the clamping mechanism to release the workpiece, allowing the machine to be pushed to the next process via casters / guide rails. The controller automatically switches to the task parameters for the next component, executing a repetitive inspection-alignment-assembly process to achieve continuous, automated batch processing.

[0083] In summary, the controller is configured to receive the docking port position information collected by the detection mechanism 50 and perform a real-time comparison based on the preset spatial coordinates corresponding to the fixing hole numbers. The controller first controls the lifting end 110 to perform an initial Z-axis adjustment on the assembly platform 20. The six-degree-of-freedom adjustment mechanism 40 connected thereto then fine-tunes the relative posture of the assembly platform 20 so that the central axis of the fixing hole on the battery pack accessory is coaxial with the axis of the docking port. The controller integrates a motion control algorithm and a path planning module to support automatic alignment of multiple fixing holes according to their numbering sequence.

[0084] In this embodiment, the lifting end 110 of the base 10 cooperates with the adjustment mechanism 40, the transmitting unit and the detection mechanism 50 are used to collect the position information of the docking interface in real time, and the movement of the lifting end 110 and the adjustment end is precisely controlled by the controller, so that the fixing holes of the battery pack accessories on the assembly platform 20 are automatically and precisely aligned with the docking interface. Therefore, the problems of low operating efficiency and high labor intensity in the manual alignment of the docking interface and the fixing holes in the prior art are effectively solved, thereby achieving a significant improvement in the processing efficiency of the battery pack accessories, a significant reduction in labor intensity, and stable and reliable assembly quality.

[0085] In some embodiments, as Figure 3 As shown, the adjustment mechanism 40 also includes a number of elastic support members 420, each of which is arranged between the assembly platform 20 and the lifting end 110, and each of the elastic supports is arranged at equal intervals around the edge of the bottom of the assembly platform 20. In a specific embodiment, the number of elastic support members 420 is determined according to the shape of the assembly platform 20. Taking the assembly platform 20 as a rectangular flat plate as an example, the number of elastic support members 420 is four, and the four elastic support members 420 are respectively arranged at the four corners of the assembly platform 20 away from the material loading platform, thereby further ensuring that the assembly platform 20 remains stable during posture adjustment. The elastic support members 420 can be specifically embodied as high-strength springs. When the posture of the assembly platform 20 changes, each elastic support member 420 undergoes tension and compression changes to apply a reaction force to the bottom of the assembly platform 20, thereby making the assembly platform 20 run more stably.

[0086] In some embodiments, as Figure 2 As shown, the transmitting unit is a magnet or a controlled electromagnet. The sensor assembly 540 is a magnetic sensor array, which includes a plurality of three-axis magnetic sensors. Each of the magnetic sensors is arranged in a two-dimensional array, and the center of the two-dimensional array coincides with the center of the assembly slot 531. Furthermore, the two-dimensional array is a rectangular array, and the spacing between each pair of adjacent magnetic sensors is equal.

[0087] In this embodiment, the launch unit is mounted near the docking port using a permanent magnet or a controlled electromagnet. Its shape can be cylindrical, rectangular, or flat, and its dimensions should be designed to ensure it does not interfere with the proper functioning of the docking port. The launch unit generates a magnetic field that can be sensed by the magnetic sensor. Its installation position is precisely calibrated to ensure a fixed, known spatial offset vector (e.g., offset vectors Δx, Δy, and Δz) relative to the muzzle center. This offset can be pre-set in the controller for compensation calculations.

[0088] The sensor assembly 540 in the detection mechanism 50 utilizes a magnetic sensor array structure, specifically composed of multiple three-axis magnetic sensors arranged in a two-dimensional rectangular array. Each three-axis magnetic sensor can detect magnetic field strength in the X, Y, and Z directions, exhibiting high sensitivity and low noise. The magnetic sensors can be Hall effect sensors or GMR (giant magnetoresistance) sensors, both of which are capable of sensing very small magnetic fields. The center of the array coincides with the center of the mounting slot 531 of the substrate 530. This ensures that when the docking port is vertically aligned with the center of the mounting slot 531, the transmitting unit will also be located in the center of the magnetic sensor array, facilitating position calculation.

[0089] The spacing between adjacent sensors in the array remains consistent (e.g., 10 mm to 15 mm) to achieve an evenly spaced grid distribution. The entire array is integrated within or on the surface of substrate 530 and isolated from external magnetic fields by shielding materials to improve signal-to-noise ratio and interference resistance.

[0090] When the docking port approaches the monitoring area formed by the detection mechanism 50 during operation, the magnetic field generated by the magnetic launcher at its muzzle generates an induction signal in the magnetic sensor array. Because the three-axis magnetic sensor can simultaneously output magnetic flux density values in the X, Y, and Z directions, the controller can use a magnetic field distribution fitting algorithm or an inverse solution algorithm to calculate the precise three-dimensional coordinates of the launcher in space based on the differences and distribution patterns of the magnetic field strength detected by each sensor.

[0091] The controller further calculates the real-time spatial position of the docking port, combining the launch unit's offset parameters relative to the docking port. It then compares this position with the preset coordinates of the mounting holes on the battery pack assembly, calculates the positional deviation, and drives the linkage between the lifting end 110 of the base 10 and the six-degree-of-freedom adjustment mechanism 40 to fine-tune the assembly platform 20, ultimately aligning the central axis of the mounting holes with the muzzle axis.

[0092] Throughout the entire process, the magnetic sensor array provides real-time, multi-dimensional, non-contact position perception with the advantages of fast response, high accuracy, and no influence from light / dust / oil, making it extremely suitable for high-precision positioning requirements in complex production environments.

[0093] This embodiment uses a magnetic sensor array to detect the position of the transmitter unit. Compared to traditional methods such as manual aiming, this method is non-contact, highly responsive, and highly resistant to interference. It is suitable for complex industrial environments such as those subject to dust, oil, and vibration. It also achieves three-dimensional real-time positioning of the interface, facilitating dynamic adjustment and error compensation. Furthermore, it supports batch automation processes, significantly improving assembly efficiency and reducing operator workload.

[0094] In some embodiments, in order to improve the accuracy and stability of magnetic field monitoring, a magnetic shielding layer is integrated inside the substrate 530 to shield the interference of the material of the battery pack accessories themselves on the magnetic field distribution.

[0095] The magnetic shielding layer is arranged below or in the surrounding area of the magnetic sensor array of the substrate 530, between the magnetic sensor and the battery pack accessory, thereby effectively isolating the magnetic influence from the battery pack accessory body. The shielding layer can be a whole block structure, or it can be cut into local rectangular blocks according to the sensor array area. The material of the magnetic shielding layer can be selected from soft magnetic alloys with high magnetic permeability and low remanence, such as μ-metal, Permalloy, iron-silicon alloy, etc. Its thickness is generally 0.1mm to 0.5mm, and is designed according to the required shielding strength and structural space.

[0096] In practical applications, battery pack components are typically made of aluminum alloy, stainless steel, or weakly magnetic steel. These materials may have inherent magnetic permeability or be magnetized during processing, causing localized disturbances in the applied magnetic field (from the transmitting unit) detected by the magnetic sensor. For example, when the edge of an aluminum profile approaches a magnetic sensor, irregular magnetic flux distortion occurs in the sensor area, causing measurement errors. The magnetic shielding layer, through its strong absorption and guidance of magnetic flux, directs these interfering magnetic fields from the workpiece into the shielding layer, preventing them from entering the effective sensing area of the magnetic sensor array. This significantly reduces the background noise of the magnetic sensor output.

[0097] During operation, the transmitter unit enters the monitoring area above assembly slot 531 and releases a magnetic field. This magnetic field passes through the monitoring area and enters the sensing layer of the magnetic sensor array. In a structure with a magnetic shielding layer, the disturbance caused by the device under test in this magnetic field is absorbed and isolated by the shielding layer, allowing the sensor to sense only the main magnetic field distribution from the transmitter unit, thereby improving the resolution and repeatability of position detection.

[0098] The magnetic shielding layer in this embodiment effectively suppresses background interference from the battery pack components or assembly platform 20 on magnetic field measurements, improving the signal-to-noise ratio of the magnetic sensor array, making positioning data more stable and reliable, and reducing system calibration errors caused by differences in component material properties. This facilitates the use of magnets with lower magnetic strength in the transmitting unit, thereby improving the energy efficiency and safety of the entire system.

[0099] In summary, the provision of the magnetic shielding layer effectively improves the working stability and positioning accuracy of the magnetic sensor array in complex metal environments, and is an indispensable component for achieving high-reliability assembly automatic alignment detection.

[0100] In order to better control the operation of the above-mentioned transfer equipment, so that the detection mechanism 50 on the transfer equipment and the transmitting unit at the interface can cooperate better, a control method is also proposed. Figure 5 , specifically including:

[0101] Step S100: Acquire the size parameters of the battery pack assembly and the target position parameters of the center point of the fixing hole of the battery pack assembly in space when the battery pack assembly is fixed on the material plane 210 by the clamping and positioning mechanism 30;

[0102] Step S200 acquires real-time detection data of each of the three-axis magnetic sensors in the magnetic sensor array provided in the detection mechanism 50 of the transfer device, wherein the real-time detection data includes a magnetic flux density value in each axial direction at a position corresponding to the location of the three-axis magnetic sensor;

[0103] Step S300 determines whether the real-time detection data of all the three-axis magnetic sensors in the magnetic sensor array meet a target matching condition, where the target matching condition includes:

[0104] The distribution of the magnetic flux density values of all the three-axis magnetic sensors satisfies a symmetry judgment condition, or;

[0105] The distance between the real-time spatial position of the transmitting unit calculated based on the magnetic flux density values of all the three-axis magnetic sensors and the spatial position of the center point of the target fixing hole on the battery pack assembly is less than a preset tolerance threshold;

[0106] In step S400, if the real-time detection data of all the three-axis magnetic sensors in the magnetic sensor array meet the target matching condition, the adjustment end of the adjustment mechanism 40 is controlled to stop moving so that the target fixing hole on the battery pack accessory is coaxial with the docking interface space.

[0107] The step S100 of obtaining the size parameters of the battery pack assembly and the target position parameters of the center point of the fixing hole of the battery pack assembly in space when the battery pack assembly is fixed on the material plane 210 by the clamping and positioning mechanism 30 includes the following steps:

[0108] S101 inputs or imports the CAD model or structural drawing information of the battery pack accessories to obtain its global size parameters and the structural layout position of the fixing holes in the body coordinate system.

[0109] Dimensional parameters include but are not limited to the length, width, height, hole diameter, hole spacing, edge distance and other geometric parameters of the accessory;

[0110] The CAD model can be a three-dimensional model (such as STEP, IGES format) or a two-dimensional engineering drawing (such as DXF, DWG, etc.);

[0111] The acquisition method can be through data interface, MES system, cloud platform data call, user manual input, etc.

[0112] S102 establishes a fixed reference coordinate system on the assembly platform 20 according to the structural parameters and constraint mode of the clamping and positioning mechanism 30 , and converts the hole coordinates in the CAD model into the spatial reference system of the assembly platform 20 .

[0113] Assuming that the clamping mechanism adopts a 4-point symmetrical jaw clamping method, its contact surface can be defined as an XY plane that coincides with the material placement plane 210, and the center point of the material placement plane 210 is the coordinate origin;

[0114] The local coordinate system in the CAD model (such as the center or corner of the component) is converted to the coordinate system associated with the assembly platform 20, and the target spatial coordinate Pn (xn, yn, zn) of each fixing hole is calculated.

[0115] S103 writes the spatial coordinate parameters (including numbers and corresponding spatial coordinates) of all target fixing hole centers obtained above into a controller data module or memory as target reference points for subsequent automatic adjustment.

[0116] This data may be stored in the controller in tabular form.

[0117] To summarize, the core of step S100 is to map the theoretical structural coordinates of the accessory to the actual spatial coordinate system of the assembly platform 20, and determine the spatial center point of each fixing hole based on the clamping and positioning structure, providing a coordinate reference for the subsequent inverse analysis of the magnetic sensor data, and ensuring that the control logic has a mathematical relationship between the "target point" and the "detection point".

[0118] The step S200 of acquiring real-time detection data of each of the three-axis magnetic sensors in the magnetic sensor array provided in the detection mechanism 50 of the transfer device, wherein the real-time detection data includes the magnetic flux density value in each axial direction at the position where the three-axis magnetic sensor is located, comprises the following steps:

[0119] Step S201 initializes the magnetic sensor array and the data reading module of the controller:

[0120] After the controller starts the detection mechanism 50, it establishes communication with the magnetic sensor array arranged on the substrate 530 through the bus interface;

[0121] Each magnetic sensor is configured in three-axis mode, outputting the magnetic flux density values in three directions (X, Y, and Z axes) of its current spatial point, usually in Gauss (Gs) or microtesla (µT);

[0122] The controller sets the reading frequency (eg, 100 Hz to 1 kHz) to achieve real-time high-frequency sampling.

[0123] Step S202: The three-axis magnetic sensor continuously collects the magnetic flux density value at the spatial point where it is located:

[0124] Each magnetic sensor is embedded with a Hall element or giant magnetoresistance (GMR) element. When an external magnetic field passes through the sensor, it generates perceptible electrical signals in the X, Y, and Z directions.

[0125] The sensor's internal circuit amplifies, filters, and converts the original signal into a digital signal, outputting the magnetic flux density values (unit: µT) in the three axial directions Bx, By, and Bz.

[0126] Each magnetic sensor periodically transmits its current coordinates and magnetic flux density value back to the controller, for example:

[0127] Sensor #1: , , ;

[0128] Sensor #2: , , ; ...

[0129] In step S203, the controller collects, caches, and uniformly calibrates the data sent back by all magnetic sensors, and establishes a data matrix according to the spatial position for subsequent calculation of the spatial position of the transmitting unit.

[0130] The controller constructs a three-dimensional magnetic field distribution map (magnetic field vector field), and each sensor corresponds to a vector ;

[0131] The controller can optionally calculate the modulus value (i.e. magnetic field strength): . Used to judge the proximity of the transmitting unit;

[0132] The controller may also use the various directional values to perform three-dimensional fitting respectively to inversely solve the precise position of the transmitting unit in space (see subsequent step S300 );

[0133] At the same time, spatial constraint relationships such as "symmetry", "peak distribution center", and "multi-point difference" can also be established.

[0134] It should be noted that the three-axis magnetic flux density values Bx, By, and Bz in step S200 represent the components of the magnetic field in three orthogonal directions at the location of the sensor, and their units are µT (microtesla). Together, they form a magnetic field vector , describes the strength and direction of the magnetic field. Among them, Bx is the component of the magnetic field on the X axis (usually the left and right direction), By is the component of the magnetic field on the Y axis (usually the front and back direction), and Bz is the component of the magnetic field on the Z axis (usually the vertical direction). Represents the total strength (modulus) of the magnetic field at that point.

[0135] Moreover, in this transfer equipment control method, the role of the three-axis magnetic flux density value is crucial, which is specifically reflected in the following aspects:

[0136] First, because the transmitting unit is a magnetic body (magnet or electromagnet), when it enters the magnetic sensor array area, it will induce different magnetic flux density values at different locations in the array. The controller can infer the spatial position change of the magnetic source by comparing the changes in the Bx, By, and Bz values output by the sensor;

[0137] Secondly, by constructing a magnetic field distribution map, the controller uses a spatial inverse solution algorithm (such as least squares, multi-point interpolation, neural network fitting, etc.) to fit the "magnetic peak center" in the distribution into a spatial coordinate, thereby determining the current three-dimensional position of the transmitting unit;

[0138] Then, by comparing the symmetry, gradient change, uniformity, or deviation of the center peak from the target point between the magnetic flux density values of multiple sensors, it is determined whether the docking interface has reached a coaxial state with the fixing hole of the battery pack accessory;

[0139] Next, the three-axis data can be used to determine whether there is a non-coplanar posture deviation. For example, if the launch unit deviates from the center of the XY plane but the magnetic field strength does not drop significantly, the change in the Z-axis value can be used to detect whether the muzzle is too high or too low.

[0140] Finally, the three-axis joint measurement avoids the problem of single-axis measurement being allergic to errors, and can make redundant judgments based on the stability of certain axis data to improve robustness.

[0141] In some embodiments of the present invention, the control method includes step S300, i.e., determining whether the real-time detection data of all the three-axis magnetic sensors in the magnetic sensor array meet a target matching condition. The target matching condition includes any one of the following two determination methods:

[0142] First, the distribution of magnetic flux density values across all three-axis magnetic sensors meets the symmetry criteria. This approach is based on the following principle: when the transmitting unit is near the center of the magnetic sensor array, the magnetic field it generates exhibits a nearly symmetrical distribution across the sensor array, meaning that the magnetic flux density measured at each sensor has minimal variation.

[0143] The specific steps include:

[0144] S301: The controller collects the Bx, By, and Bz values output by each three-axis magnetic sensor and calculates the modulus of its magnetic field strength: .

[0145] S302: Constructing a magnetic field strength set for all sensors , calculate the range D and standard deviation σ of the magnetic field intensity:

[0146] ; ; .

[0147] S303: Compare D with a first threshold value ε, and σ with a second threshold value δ. If D ≤ ε and σ ≤ δ (for example, ε = 3 μT, δ = 1.5 μT), the magnetic flux density is determined to be symmetrically distributed in the array, indicating that the transmitting unit is located near the center of the array and the corresponding docking port is close to the coaxial position of the target fixing hole.

[0148] In practical applications, the first threshold ε and the second threshold δ can be set through experimental calibration. Specifically, with the transmitting unit in a coaxial state, multiple sets of magnetic sensor magnetic flux density data are collected, the magnetic field intensity range and standard deviation are calculated, and the thresholds are determined based on the maximum value with a margin added. This setting method ensures the stability and robustness of symmetry judgment and adapts to signal fluctuations in production environments.

[0149] The first threshold, ε, is the magnetic field intensity extreme value threshold; the second threshold, δ, is the magnetic field intensity standard deviation threshold. These thresholds are used to determine whether the magnetic flux density distribution in the magnetic sensor array is sufficiently symmetrical, that is, to determine whether the transmitting unit is located at the center of the magnetic sensor array. The following is the method for determining the thresholds:

[0150] This method is suitable for the system initialization stage in the laboratory or production site, using actual emission units and multiple sampling to establish the upper and lower threshold limits.

[0151] The first step is to build a test environment, install the magnetic sensor array on the target detection platform, use the actual docking interface and launch unit, and set 5 to 10 launch unit alignment points at different locations (including the center and the periphery).

[0152] The second step is to record sensor data in the coaxial state. The moving mechanism is controlled to align the center of the transmitting unit with the center of the assembly slot 531 (i.e., the ideal position). The magnetic flux density Bi (calculated as modulus) of all three-axis magnetic sensors in the magnetic sensor array is recorded in this state. Multiple sets of data (e.g., 30 times) are recorded to mitigate the effects of ambient noise.

[0153] The third step is to calculate the ideal range of D and σ values, once for each set of samples.

[0154] Range D = max (Bi) – min (Bi); standard deviation ;

[0155] Count all the values of D and σ and find the mean respectively 、 and maximum values Dmax and σmax.

[0156] Furthermore, a margin Δε (for example, a margin of Δε=10% to 20%) and a margin Δδ (a margin of Δδ=10% to 20%) may be set. In this case, the first threshold ε=Dmax+Δε; the second threshold δ=δmax+Δδ.

[0157] For example, when sampling 30 times in the coaxial state, the maximum D value measured is 2.8μT and the maximum σ is 1.3μT.

[0158] Then we can set: the first threshold ε=2.8+0.5=3.3μT (rounded up to 3.5μT); the second threshold δ=1.3+0.3=1.6μT (rounded up to 1.8μT).

[0159] The fourth step is to verify the robustness of the threshold. Test 20 to 50 times in a non-coaxial state (eccentricity ±1mm, ±2mm, etc.) to confirm that the calculated D and σ are significantly greater than the set threshold. If there is a cross misjudgment, the margin needs to be adjusted appropriately. 、 .

[0160] Secondly, the real-time spatial position of the launch unit is calculated based on the magnetic flux density value and compared with the spatial coordinates of the target fixed hole. This method is suitable for higher-precision alignment control and is specifically implemented as follows:

[0161] S310: The controller collects the spatial coordinates Pi = (xi, yi, zi) of each sensor and the corresponding magnetic flux density vector Bi = (Bxi, Byi, Bzi) to construct a magnetic field distribution point set: .

[0162] S311: Based on the magnetic field distribution, the controller uses a fitting inverse algorithm to calculate the spatial position of the transmitting unit Pm = (Xm, Ym, Zm). The calculation method includes the weighted center method: , , ; or reversely deduce the magnetic source coordinates Pm based on the magnetic dipole physical model.

[0163] S312: Compare the real-time transmitting unit position Pm with the preset target fixing hole center position Pt=(Xt, Yt, Zt) to calculate the spatial distance: .

[0164] S313: If d ≤ a set tolerance threshold T (eg, T = 0.3 mm), it is determined that the docking port and the central axis of the target fixing hole have achieved spatial coaxiality, thereby satisfying the target matching condition.

[0165] Among them, the setting of the tolerance threshold T is related to the judgment of the spatial coaxial accuracy of the docking interface and the fixing hole on the battery pack accessory. In the present application, T is used to judge whether the spatial distance between the real-time position Pm of the transmitting unit obtained by inverse solution of the magnetic flux density and the center point Pt of the target fixing hole meets the accuracy requirements. In order to ensure the spatial coaxiality of the docking interface and the central axis of the target fixing hole, the tolerance threshold T can be determined based on the assembly process tolerance, the error capability of the magnetic positioning system and the control accuracy of the actuator. Specifically, the allowable deviation ΔP is first determined by the assembly and installation standard, and then the system inverse error ΔM is obtained through actual testing. Combined with the minimum response granularity ΔC of the adjustment mechanism 40, the maximum value of the three is taken and a safety margin is added to obtain the tolerance threshold T. For example, when ΔP and ΔM are 0.3mm, ΔC is 0.05mm, and the safety margin is 0.05mm, T=0.4mm can be set to judge whether the spatial alignment meets the requirements. The following are the detailed steps and methods for determining the tolerance threshold T:

[0166] T is the maximum spatial error threshold allowed by the system. If d≤T, the muzzle and the fixing hole are considered coaxial. The setting of T needs to take into account the following three aspects:

[0167] Assembly process (e.g. rivet process) requirements for coaxial accuracy (source of accuracy requirements).

[0168] The actual ability of the system to position the error (source of measurement accuracy).

[0169] Minimum resolution for controlling execution accuracy (source of response accuracy).

[0170] The determination of T specifically includes the following steps:

[0171] The first step is to determine the maximum allowable deviation ΔP (accuracy requirement) for the assembly process. Consult the assembly manufacturer's or mechanical structure's tolerance specifications to determine the maximum positioning deviation for the fixing hole or the centering requirement for the assembly insertion. For example, for common blind rivets with a diameter of 4.8mm to 6.4mm, the recommended hole alignment deviation is ≤±0.3mm to 0.4mm. Specifically, consider ΔP = 0.3mm (the maximum allowable deviation between the center axis of the mating interface and the hole axis).

[0172] The second step is to evaluate the system's actual solution error ΔM (positioning accuracy capability). After the system is set up, control the transmitter to move to multiple known positions (e.g., 10). Each time, record the error di between the position Pm obtained by the magnetic sensor array and the actual position. Calculate the mean error μ and standard deviation σ. For example, μ = 0.15mm, σ = 0.05mm, and the maximum error dmax = 0.25mm. Assuming ΔM = dmax + Δ safety margin (e.g., Δ = 0.05mm), we can deduce that ΔM ≈ 0.30mm.

[0173] The third step is to confirm the system execution accuracy ΔC (the control accuracy of the six-degree-of-freedom platform 410 or the slide). This can be determined by looking up the minimum stepping accuracy of the adjustment mechanism 40 (e.g., six-axis platform, lead screw module) or the lifting platform. For example, if the positioning resolution of the control platform is 0.05mm and the repeatability is ±0.02mm, ΔC = 0.05mm can be set as the minimum response granularity of the control system.

[0174] The fourth step is to comprehensively determine the tolerance threshold T.

[0175] T should simultaneously satisfy the following: T ≥ ΔP (to meet process requirements), T ≥ ΔM (to cover error), and T ≥ ΔC (to ensure control response). Furthermore, it is recommended to take the maximum value and add a safety margin: T = max{ΔP, ΔM, ΔC} + Δsafety.

[0176] For example: ΔP=0.3mm, ΔM=0.3mm, ΔC=0.05mm, ΔSafety=0.05mm.

[0177] The final tolerance threshold is set to: T = 0.3 + 0.05 = 0.35 mm (rounded up to 0.4 mm).

[0178] Furthermore, the two aforementioned determination methods can be combined. The controller can first achieve rapid, rough positioning based on symmetry, and then accurately determine whether spatial coaxiality has been achieved through spatial distance comparison. This balances determination speed and accuracy, improving the robustness and efficiency of the control system.

[0179] It should be noted that the aforementioned "relative positional relationship between the docking port center position and the transmitting unit is a known quantity" requires a coordinate transformation mechanism to infer the real-world spatial coordinates of the docking port from the position of the transmitting unit detected by the magnetic sensor array. This is a typical spatial geometry transformation problem, essentially using a coordinate system transformation to map the position of the transmitting unit to the position of the docking port, thereby achieving precise alignment of the fixing holes. The detailed processing method is as follows:

[0180] Assume that the real-time position of the transmitting unit in space is Pf=(X f ,Y f ,Z f ), calculated by the magnetic sensing array.

[0181] Assume that the spatial offset of the transmitting unit relative to the docking interface is Δ= (Δx, Δy, Δz). This value is a design parameter and has been measured during installation.

[0182] Assume the center position of the docking port is Pg = (Xg, Yg, Zg), which is the target alignment coordinate required by the controller. Then: This relationship indicates that the true position of the muzzle is obtained by deducting the known offset Δ from the calculated position Pf of the firing unit.

[0183] Among them, Δ can be obtained through a one-time measurement after the launch unit leaves the factory or is assembled, for example: align the docking port with the center of the tooling on the test bench and record the launch unit position Pf calculated by the magnetic sensor array at this time. . Δ is written into the controller's internal configuration parameter table and used as a coordinate offset during the entire operation process.

[0184] In step S400, if the real-time detection data of all the three-axis magnetic sensors in the magnetic sensor array meet the target matching condition, the adjustment end of the adjustment mechanism 40 is controlled to stop moving so that the target fixing hole on the battery pack accessory is coaxial with the docking interface space.

[0185] Specifically, in step S400, when the controller determines through step S300 that the real-time spatial position of the transmitting unit meets the preset target matching conditions (including that the magnetic field intensity distribution meets the symmetry or the spatial distance between the real-time position and the center point of the target fixing hole is less than the tolerance threshold T), it is considered that the current docking interface position has achieved spatial coaxiality with the central axis of the target fixing hole, and the position locking state is entered at this time.

[0186] The controller sends a motion stop instruction to the adjustment mechanism 40 according to the judgment result, specifically including:

[0187] For the adjustment mechanism 40 based on the six-degree-of-freedom platform 410, the controller sends a stop command to each servo screw assembly 413 or the execution motor to keep the position of each degree of freedom at the current state.

[0188] For the slide structure or other linear adjustment mechanism 40, its driving device (such as a servo motor or a stepper motor) is controlled to turn off the output and enter the position holding mode.

[0189] The purpose of stopping the movement of the adjustment end of the adjustment mechanism 40 is to ensure that the battery pack assembly is in an aligned state and to prevent it from causing an offset error due to continued movement during the assembly process.

[0190] Furthermore, if the system incorporates a position-holding function (such as a platform brake or holding brake), the controller can also issue a locking control signal to ensure the stability of the platform when stationary. Furthermore, if the controller features real-time error monitoring, it can maintain real-time acquisition of magnetic sensor data even after motion stops. If it detects position deviation outside the set tolerance, it can trigger a fine-tuning command again for dynamic compensation.

[0191] In summary, the above control method can ensure that the spatial center axis of the target fixing hole and the center axis of the docking interface remain collinear in the three-dimensional coordinate system, providing a precise hole position matching basis for subsequent high-quality assembly.

[0192] In some optional embodiments, the control method further includes: Step S500 , to enhance the accuracy of the determination, a component (e.g., screw, rivet, etc.) insertion detection unit (not shown) may be provided within the docking interface. When the component insertion detection unit reports that the component has entered the fixing hole and the insertion depth has reached a threshold, the controller determines that alignment and insertion are complete, stops the adjustment mechanism 40, and begins assembly. This step provides a multiple confirmation mechanism for component installation.

[0193] This step introduces a physical action confirmation mechanism based on steps S300 and S400 as a redundant verification path for the magnetic field detection results, which is used to enhance the accuracy and robustness of the system under complex working conditions (such as slight deviations, vibrations, etc.).

[0194] The assembly insertion detection unit can utilize photoelectric sensors (transmissive or reflective), contact-type micro switches / pressure sensors, resistance / capacitance sensors, or displacement / travel encoders. Photoelectric sensors are located within the docking port or near the assembly exit. Insertion is indicated when the assembly enters the gun through the feed channel and partially extends, blocking the light beam or reflecting a signal. These sensors are mounted in a two-beam, one-receiver setup, either on opposite sides of the assembly guide rail or flush-mounted against the inner wall of the assembly exit. They offer fast response, are suitable for small-diameter assemblies, and are non-contact and wear-free. Contact-type micro switches / pressure sensors utilize a spring-loaded mechanism at the assembly exit. A travel detection signal is triggered when the front end of the assembly contacts the bottom or edge of the hole. These sensors are embedded in the sidewall or bottom of the docking port, and utilize a compressible contact mechanism. These sensors offer a simple structure and are suitable for detecting and confirming holes of known dimensions. Resistance / capacitance change sensing refers to the formation of a closed circuit or capacitance / resistance change after an assembly is inserted into a hole. For example, a metal assembly (screw, rivet) contacts the metal hole wall, forming a circuit. This is achieved by placing an electrode or detection needle at the muzzle, connected to the assembly platform at 20° potential, to form an electrical closed loop monitoring system. This offers the advantage of providing clear electrical feedback between the "inserted" and "uninserted" states. A displacement / stroke encoder uses an encoder to record the assembly's displacement in real time by coordinating with the assembly's push rod. Insertion is considered complete when the push rod reaches the set insertion stroke (e.g., 8mm). The displacement sensor is installed inside the docking port, and the encoder is connected to the power unit (cylinder / servo) that pushes the assembly.

[0195] Step S500 includes the following steps:

[0196] S510: When the magnetic sensor array has determined that the muzzle is aligned with the fixing hole (step S400), the controller triggers the assembly push instruction to execute the insertion action;

[0197] S520: During the assembly part pushing process, the assembly part insertion detection unit starts to collect signals in real time and feedback the current insertion status;

[0198] S530: When the detection signal satisfies the following two conditions, it can be determined that the insertion is completed.

[0199] Among them, the insertion detection signal is valid (such as shading, triggering, closing, capacitance change, etc.), and the insertion depth reaches the preset value L (such as L≥7mm, which can be set by the system).

[0200] S540: After receiving the completion signal, the controller immediately controls the adjustment mechanism 40 to stop moving, and activates the assembly program to enter the next process.

[0201] The above contents described in this specification are merely examples of the present invention. Those skilled in the art may make various modifications, additions, or substitutions to the described embodiments, without departing from the contents of this specification or exceeding the scope defined by the claims, and such modifications, additions, or substitutions may be made to the described embodiments. Such modifications, additions, or substitutions may be made by persons skilled in the art. Such modifications, additions, or substitutions may be made to the described embodiments without departing from the contents of this specification or exceeding the scope defined by the claims, and such modifications shall fall within the scope of protection of the present invention.

Claims

1. A processing platform based on a battery pack metal shell, characterized in that: include: The assembly platform includes a material placement surface for placing battery pack accessories; A clamping and positioning mechanism connected to the assembly platform to controllably restrict the battery pack assembly to a target position on the loading plane; a base, the base including a controlled lifting end; An adjusting mechanism is provided at the lifting end, the adjusting mechanism comprising an adjusting end with controlled movement, the adjusting end being connected to the assembly platform; The transmitting unit is arranged at the docking port where the connecting piece is installed; Testing agencies, including: A travel component connected to the assembly platform, the travel component comprising a first moving end that moves in a controlled manner, wherein a moving track of the first moving end is parallel to the material placement plane; A lifting assembly connected to the first moving end, the lifting assembly including a second moving end that moves in a controlled manner, wherein a moving trajectory of the second moving end is perpendicular to the material loading plane; a base plate connected to the second movable end, the base plate including an assembly slot extending therethrough, the assembly slot being configured to be coaxially arranged with a fixing hole of the battery pack accessory on the loading plane during processing of the battery pack accessory; A sensor assembly is provided on the substrate, the sensor assembly is provided around the assembly groove to form a monitoring area, and the sensor assembly is configured to continuously collect position information of the transmitting unit when the transmitting unit enters the monitoring area; A controller is connected to the base, the adjustment mechanism and the detection mechanism, and the controller is configured to receive the position information and control the movement of the lifting end and the adjustment end according to the position information so that the fixing hole of the battery pack accessory on the material placement plane is aligned with the docking port.

2. A battery pack metal shell processing platform according to claim 1, characterized in that: The transmitting unit is a magnet or a controlled electromagnet.

3. A battery pack metal shell processing platform according to claim 2, characterized in that: The sensing component is a magnetic sensing array, which includes a plurality of magnetic sensors. The magnetic sensors are arranged in a two-dimensional array, and the center of the two-dimensional array coincides with the center of the assembly slot.

4. A battery pack metal shell processing platform according to claim 3, characterized in that: The two-dimensional array is a rectangular array, and the spacings between any two adjacent magnetic sensors are equal.

5. A battery pack metal shell processing platform according to claim 3 or 4, characterized in that: The magnetic sensor is a three-axis magnetic sensor.

6. The processing platform based on the metal shell of the battery pack according to claim 1, characterized in that: A magnetic shielding layer is provided in the substrate.

7. The processing platform based on the metal shell of the battery pack according to claim 1, characterized in that: The regulating mechanism comprises: A six-degree-of-freedom platform, connected to the controller, comprising: a first mounting seat connected to the lifting end; a second mounting seat, the second mounting seat being the adjustment end, and the second mounting seat being connected to a side of the assembly platform facing away from the material placement plane; a servo screw assembly, disposed between the first mounting seat and the second mounting seat, for adjusting the relative posture of the assembly platform in a controlled manner; A plurality of elastic support members are provided between the assembly platform and the lifting end, and the elastic supports are arranged at equal intervals around the edge of the bottom of the assembly platform.

8. The battery pack metal shell processing platform according to claim 7, characterized in that: The transmitting unit is a magnet or an electromagnet; The sensing assembly is a magnetic sensor array, which includes a plurality of three-axis magnetic sensors, each of which is arranged in a rectangular two-dimensional array, wherein the distances between any two adjacent magnetic sensors are equal, and the center of the two-dimensional array coincides with the center of the assembly slot; A magnetic shielding layer is provided in the substrate.

9. A control method for the processing platform according to claim 8, characterized in that: The processing platform further includes an assembly part insertion detection unit, which is disposed in the docking port. The control method includes: Obtaining size parameters of the battery pack accessory and target position parameters of the center point of the fixing hole of the battery pack accessory in space when the battery pack accessory is fixed on the material placement plane by the clamping and positioning mechanism; Acquiring real-time detection data of each of the three-axis magnetic sensors in the magnetic sensor array provided in the detection mechanism of the processing platform, the real-time detection data including a magnetic flux density value in each axial direction at a position corresponding to the three-axis magnetic sensor; Determine whether the real-time detection data of all the three-axis magnetic sensors in the magnetic sensor array meets a target matching condition, where the target matching condition includes: The distribution of the magnetic flux density values of all the three-axis magnetic sensors satisfies a symmetry judgment condition, or; The distance between the real-time spatial position of the transmitting unit calculated based on the magnetic flux density values of all the three-axis magnetic sensors and the spatial position of the center point of the target fixing hole on the battery pack assembly is less than a preset tolerance threshold; If the real-time detection data of all the three-axis magnetic sensors in the magnetic sensor array meet the target matching condition, controlling the adjustment end of the adjustment mechanism to stop moving so that the target fixing hole on the battery pack accessory is spatially coaxial with the docking interface; The control method further includes: When the assembly insertion detection unit reports that the assembly has entered the target fixing hole and the insertion depth has reached a threshold, the controller determines that the alignment and insertion actions have been completed.

10. The control method according to claim 9, characterized in that: The symmetry judgment conditions include: The standard deviation of the output values of the three-axis magnetic sensors in the magnetic sensor array is less than a set threshold, or; The difference between the maximum value and the minimum value of the output value is less than a preset value; The preset tolerance threshold should be within 0.3 mm.

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