Automatic assembling method for battery spare and accessory parts

Abstract

The invention relates to the technical field of battery assembly, in particular to an automatic assembly method for battery parts, which comprises the following steps: step 1, screening battery cells: detecting and sorting parameters such as voltage, internal resistance and capacity of single batteries through automatic equipment to ensure performance consistency; 2, sorting accessories: accurately positioning and feeding the accessories such as positive and negative pole pieces, diaphragms, electrolyte, connecting pieces (such as nickel pieces), shells and the like by a mechanical arm or a conveyor belt; the method comprises the following steps: detecting and sorting parameters such as voltage, internal resistance, capacity and the like of single batteries through automatic equipment, laminating and assembling through the automatic equipment, inserting a diaphragm, quantitatively injecting electrolyte by adopting a laser welding or spot welding process in a vacuum or inert gas environment, putting an assembled battery cell module into a customized shell, and carrying out mechanical pressing to obtain the battery cell module. And charging and discharging circulation, short-circuit testing and the like are carried out through automatic equipment, unqualified products are removed, and therefore the method has the advantages of being high in automation degree, effectively improving production efficiency and the like.

Description

Technical Field

[0001] This invention relates to the technical field of battery assembly, specifically to an automated assembly method for battery components. Background Technology

[0002] The assembly of battery components (such as cells, modules, covers, terminals, and current collectors) is a crucial step in battery manufacturing. The core processes for these components (such as current collector welding, tab flattening, and peripheral welding) require high precision equipment. With the rapid development of the new energy industry (such as the widespread adoption of electric vehicles and energy storage systems), market demands for battery capacity, performance, and safety are constantly increasing. Traditional manual assembly methods can no longer meet these requirements because the pace of manual assembly depends on worker speed, making continuous production impossible and failing to satisfy the large-scale production capacity demands of new energy vehicles, energy storage systems, and other fields. Summary of the Invention

[0003] (a) Technical problems to be solved

[0004] To address the shortcomings of existing technologies, this invention provides an automated assembly method for battery components, which has advantages such as high automation and improved production efficiency, thus solving the aforementioned problems.

[0005] (II) Technical Solution

[0006] To achieve the above objectives, the present invention provides the following technical solution:

[0007] An automated assembly method for battery components includes the following steps:

[0008] Step 1: Cell Screening: Automated equipment is used to test and sort individual battery cells based on parameters such as voltage, internal resistance, and capacity to ensure performance consistency;

[0009] Step 2: Component sorting: Positive and negative electrode plates, separators, electrolytes, connectors (such as nickel sheets), housings and other components are precisely positioned and fed by robotic arms or conveyor belts;

[0010] Step 3: Cell stacking and welding: After the positive and negative electrode sheets are coated and wound / stacked, they are stacked and assembled by automated equipment, and a separator is inserted. Laser welding or spot welding is used to weld the cell tabs to the connectors (such as busbars) to ensure low resistance connection.

[0011] Step 4: Inject electrolyte in a measured amount under vacuum or inert gas conditions;

[0012] Step 5: Shell Packaging: The assembled cell modules are placed into a custom shell, mechanically pressed together, and the battery management system (BMS) is electrically connected to the cell assembly;

[0013] Step Six: The battery pack undergoes charge-discharge cycles and short-circuit tests using automated equipment to remove defective products. The packaged battery pack is then pressurized or evacuated to detect leaks (the manifold sealing of the fuel cell stack requires additional testing).

[0014] Step 7: Finished product processing and packaging.

[0015] Preferably, step one further includes using an optical detector or a high-precision electronic scale to sort the battery cells / plates by weight and size to ensure consistency.

[0016] Preferably, step two can also use a vibratory feeder, a linear vibrator, or a conveyor belt to achieve the directional sorting and conveying of small parts such as copper nails and connecting pieces (e.g., copper nails are precisely positioned by a misalignment mechanism). The continuous supply and positioning of parts can be achieved by using a material conveying system in conjunction with a robotic arm or a suction cup gripper. For example, copper nails are conveyed by a feed chute in conjunction with a linear vibrator, and after the misalignment slider adjusts the position, they are pushed into the assembly station.

[0017] Preferably, in step four, the electrolyte is injected quantitatively in a vacuum or inert gas environment to avoid contamination of the electrolyte.

[0018] Preferably, step five can also be achieved by using laser to seal the customized outer casing, providing physical protection, and the battery management system (BMS) and the cell pack are electrically connected and installed inside the module or at the end plate location to realize status monitoring.

[0019] Preferably, step six also requires an aging test: simulating a long-term use environment to verify stability.

[0020] Preferably, in step seven, batch information is marked using a laser marking device, the data is uploaded to the MES system for traceability, and qualified battery packs are placed into shock-absorbing materials, packed, and labeled using a robotic arm.

[0021] (III) Beneficial Effects

[0022] Compared with the prior art, the present invention provides an automated assembly method for battery components, which has the following advantages:

[0023] 1. This invention utilizes automated equipment to detect and sort battery cells based on parameters such as voltage, internal resistance, and capacity, ensuring performance consistency. Positive and negative electrode sheets, separators, electrolytes, connectors (such as nickel sheets), and casings are precisely positioned and fed by robotic arms or conveyor belts. After coating and winding / stacking, the positive and negative electrode sheets are assembled using automated equipment and a separator is inserted. Laser welding or spot welding is used to weld the cell tabs to connectors (such as busbars) to ensure low-resistance connections. Electrolyte is quantitatively injected in a vacuum or inert gas environment. The assembled cell modules are placed in a customized casing and mechanically pressed together. The battery management system (BMS) is electrically connected to the cell assembly. Automated equipment performs charge-discharge cycles and short-circuit tests to remove defective products. The packaged battery pack is then pressurized or evacuated to detect leaks. This method offers advantages such as high automation and significantly improved production efficiency.

[0024] 2. This invention can also use vibratory feeders, linear vibrators, or conveyor belts to achieve the directional sorting and conveying of small accessories such as copper nails and connecting pieces (e.g., copper nails are precisely positioned by a misalignment mechanism). Through a material conveying system in conjunction with a robotic arm or suction cup gripper, continuous supply and positioning of accessories can be achieved. For example, copper nails are conveyed through a feeding chute in conjunction with a linear vibrator, and after the misalignment slider is adjusted in position, they are pushed into the assembly station. Furthermore, laser welding is used to seal the customized outer shell to provide physical protection. The battery management system (BMS) and the cell pack are electrically connected and installed inside the module or at the end plate position to achieve status monitoring. Detailed Implementation

[0025] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0026] This invention relates to an automated assembly method for battery components, comprising the following steps:

[0027] Step 1: Cell Screening: Automated equipment is used to test and sort individual battery cells based on parameters such as voltage, internal resistance, and capacity to ensure performance consistency;

[0028] It also includes using optical inspection instruments or high-precision electronic scales to sort battery cells / plates by weight and size to ensure consistency;

[0029] Visual inspection: Optical inspection instruments identify defects such as scratches and leakage on the electrode plates;

[0030] Step 2: Component sorting: Positive and negative electrode sheets, separators, electrolytes, connectors (such as nickel sheets), housings and other components are precisely positioned and fed by robotic arms or conveyor belts. The machine vision system guides the robotic arms to complete the component gripping and alignment with micron-level precision. Some production lines use Teflon coatings or temporary protective strips to reduce assembly friction damage.

[0031] The power battery cover is made by stamping and riveting. The copper nails and negative electrode sheets are precisely assembled by positioning molds and then stamped and fixed.

[0032] Vibratory feeders, linear vibrators, or conveyor belts can also be used to achieve the directional sorting and conveying of small parts such as copper nails and connecting pieces (e.g., copper nails are precisely positioned by a misalignment mechanism). By using a material conveying system in conjunction with a robotic arm or suction cup gripper, the continuous supply and positioning of parts can be achieved. For example, copper nails are conveyed by a feed chute in conjunction with a linear vibrator, and after the misalignment slider adjusts the position, they are pushed into the assembly station.

[0033] Step 3: Cell stacking and welding: After the positive and negative electrode sheets are coated and wound / stacked, they are stacked and assembled by automated equipment, and a separator is inserted. Laser welding or spot welding is used to weld the cell tabs to the connectors (such as busbars) to ensure low resistance connection.

[0034] Positive and negative electrode plates and separators are stacked by a robotic arm, and after electrolyte is injected, they are packaged into a battery cell. When integrating the module, the contact resistance needs to be controlled for series / parallel connections, and copper / nickel connectors with high conductivity are used.

[0035] Laser welding: used for high-precision connections (such as copper nails and connecting pieces for battery covers), with minimal heat-affected zones and strong welds;

[0036] Spot welding: Suitable for large-scale production, it achieves efficient connection (such as electrode group welding) through automated spot welding machines. Welding parameters (temperature, time, pressure) are controlled in real time by PLC to avoid incomplete welding or overheating damage.

[0037] The pneumatic cylinder applies pressure in stages to ensure the tightness of the battery cell stacking (e.g., first compress the whole cell, then release it in stages to insert it into the casing);

[0038] Step 4: Inject the electrolyte in a measured amount under vacuum or inert gas conditions to avoid contamination of the electrolyte;

[0039] Step 5: Shell Packaging: The assembled cell modules are placed into a custom shell, mechanically pressed together, and the battery management system (BMS) is electrically connected to the cell assembly;

[0040] Laser welding can also be used to seal the customized outer casing, providing physical protection. The battery management system (BMS) and the cell pack are electrically connected and installed inside the module or on the end plate to achieve status monitoring.

[0041] Step Six: The battery pack undergoes charge-discharge cycles and short-circuit tests using automated equipment to remove defective products. The packaged battery pack is then pressurized or evacuated to detect leaks (the manifold sealing of the fuel cell stack requires additional testing).

[0042] Aging tests are also required: to simulate long-term use environments and verify stability;

[0043] Step 7: Finished product processing and packaging. Batch information is marked using laser marking equipment, and the data is uploaded to the MES system for traceability. Qualified battery packs are placed in shock-absorbing material by a robotic arm, and then packed and labeled.

[0044] The processes differ for different battery types (such as lithium-ion and fuel cells). For example, fuel cell stacks require a special strapping / screw clamping structure, while energy storage batteries focus more on module-level integration. The specific production line design needs to be adjusted according to product specifications.

[0045] The beneficial effects of this invention are as follows: This invention uses automated equipment to detect and sort parameters such as voltage, internal resistance, and capacity of individual battery cells, ensuring performance consistency. Components such as positive and negative electrode sheets, separators, electrolytes, connectors (e.g., nickel sheets), and casings are precisely positioned and fed by robotic arms or conveyor belts. Vibratory feeders, direct vibrators, or conveyor belts can also be used to achieve the directional sorting and conveying of small components such as copper nails and connectors (e.g., copper nails are precisely positioned using a misalignment mechanism). Through a material conveying system in conjunction with robotic arms or suction cup grippers, continuous supply and positioning of components are achieved. After coating and winding / stacking, the positive and negative electrode sheets... The battery cells are assembled in layers using automated equipment, and a separator is inserted. Laser welding or spot welding is used to weld the cell tabs to the connectors (such as busbars) to ensure low-resistance connections. Electrolyte is injected in a metered manner in a vacuum or inert gas environment. The assembled cell modules are placed in a custom-designed casing and mechanically pressed together. The battery management system (BMS) is electrically connected to the cell assembly. The battery undergoes charge-discharge cycles and short-circuit tests using automated equipment to remove defective products. The packaged battery pack is then pressurized or evacuated to detect leaks. This method has the advantages of high automation and improved production efficiency.

[0046] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An automated assembly method for battery components, characterized in that, Includes the following steps: Step 1: Cell Screening: Automated equipment is used to test and sort individual battery cells based on parameters such as voltage, internal resistance, and capacity to ensure performance consistency; Step 2: Component sorting: Positive and negative electrode plates, separators, electrolytes, connectors (such as nickel sheets), housings and other components are precisely positioned and fed by robotic arms or conveyor belts; Step 3: Cell stacking and welding: After the positive and negative electrode sheets are coated and wound / stacked, they are stacked and assembled by automated equipment, and a separator is inserted. Laser welding or spot welding is used to weld the cell tabs to the connectors (such as busbars) to ensure low resistance connection. Step 4: Inject electrolyte in a measured amount under vacuum or inert gas conditions; Step 5: Shell Packaging: The assembled cell modules are placed into a custom shell, mechanically pressed together, and the battery management system (BMS) is electrically connected to the cell assembly; Step Six: The battery pack undergoes charge-discharge cycles and short-circuit tests using automated equipment to remove defective products. The packaged battery pack is then pressurized or evacuated to detect leaks. Step 7: Finished product processing and packaging.

2. The automated assembly method for battery components according to claim 1, characterized in that: Step one also includes using an optical inspection instrument or a high-precision electronic scale to sort the battery cells / plates by weight and size to ensure consistency.

3. The automated assembly method for battery components according to claim 1, characterized in that: Step two can also use a vibratory feeder, a linear vibrator, or a conveyor belt to achieve the directional sorting and conveying of small parts such as copper nails and connecting pieces. By using a material conveying system in conjunction with a robotic arm or a suction cup gripper, the continuous supply and positioning of parts can be achieved.

4. The automated assembly method for battery components according to claim 1, characterized in that: In step four, the electrolyte is injected quantitatively in a vacuum or inert gas environment to avoid contamination of the electrolyte.

5. The automated assembly method for battery components according to claim 1, characterized in that: Step five can also be achieved by using laser to seal the customized outer casing, providing physical protection. The battery management system (BMS) is electrically connected to the cell pack and installed inside the module or on the end plate to achieve status monitoring.

6. The automated assembly method for battery components according to claim 1, characterized in that: Step six also requires an aging test: simulating a long-term use environment to verify stability.

7. The automated assembly method for battery components according to claim 1, characterized in that: In step seven, batch information is marked using a laser marking device, and the data is uploaded to the MES system for traceability. A robotic arm then places the qualified battery packs into shock-absorbing material, packs them, and labels them.