All-vanadium redox flow battery stack automation device and method

Abstract

The invention discloses an all-vanadium redox flow battery stack automation device and method, and relates to the technical field of redox flow battery stack assembly. The mechanical arm comprises a first mechanical arm body, a second mechanical arm body, a transfer suction cup assembly, a transposition assembly and a central control system. The two mechanical arms are symmetrically installed on a rotary disc of the transposition assembly, and station switching is achieved. The transfer suction cup assembly is arranged at the tail end of the mechanical arm, adopts a plurality of independently-controlled flexible suction cups and is provided with a pressure sensor and an electromagnetic valve. A stack assembly station is integrated with a pressure monitoring module to realize closed-loop control of stacking force; the central control system coordinates operation of all the components through the industrial Ethernet, and automatic material taking, transferring, handover and precise stacking of the single batteries are completed. According to the invention, through a double-arm cooperation and rotation transposition mechanism, path interference is avoided, and the working efficiency and the space utilization rate are improved; by combining controlled stacking and real-time state monitoring, the assembly precision of the electric pile is remarkably improved, and efficient, intelligent and automatic production of the electric pile of the all-vanadium redox flow battery is realized.

Description

Technical Field

[0001] This invention belongs to the field of flow battery stack assembly technology, and in particular relates to an automated device and method for an all-vanadium redox flow battery stack. Background Technology

[0002] Vanadium redox flow batteries, as a large-scale energy storage technology with advantages such as long life, high safety, deep charge and discharge capability, and independent design of power and capacity, have shown broad application prospects in renewable energy grid connection, grid peak shaving, and backup power in recent years. The stack, as its core component, is a layered structure composed of dozens to hundreds of battery cells (including graphite bipolar plates, ion exchange membranes, electrode frames, etc.) through precise stacking, compression, and sealing.

[0003] The assembly process of flow battery stacks still commonly relies on manual operation or semi-automated equipment. Traditional assembly methods typically involve operators manually handling battery cells and stacking them layer by layer on an assembly platform, then securing them with external clamping mechanisms. This method is not only labor-intensive and inefficient, but also suffers from uneven force, inaccurate positioning, and the introduction of dust or scratches due to manual operation. This results in poor stacking consistency, large fluctuations in contact resistance, and a high risk of seal failure, severely impacting battery performance stability and product yield. While existing technologies introduce industrial robots for battery cell handling and stacking, some limitations remain. For example, when using a single robotic arm system, the arm needs to frequently move between the battery supply area and the assembly area, leading to long cycle times and low space utilization.

[0004] To address these issues, we provide an automated device and method for a vanadium redox flow battery stack. Summary of the Invention

[0005] The purpose of this invention is to provide an automated device and method for vanadium redox flow battery stacks. By adopting a symmetrical layout of dual robotic arms combined with a transposition component, and integrating a high-precision transfer chuck, a pressure feedback assembly station, and a central collaborative control system, it solves the problems of low battery cell assembly efficiency, poor stacking accuracy, excessive manual intervention, easy mechanical interference, and lack of real-time force control and safety monitoring in the prior art.

[0006] To solve the above-mentioned technical problems, the present invention is achieved through the following technical solution:

[0007] This invention relates to an automated device for a vanadium redox flow battery stack, comprising a first robotic arm, a second robotic arm, a transfer suction cup assembly, a transposition assembly, and a central control system. The first and second robotic arms are symmetrically arranged and jointly mounted on a turntable of the transposition assembly. A base is mounted on the outside of the turntable, and the turntable rotates in conjunction with the base via a rotary driver. The transfer suction cup assembly is fixedly mounted on the end effectors of the first and second robotic arms, and includes a suction cup bracket, multiple suction cups disposed at the lower part of the suction cup bracket, and a vacuum generator connected to the multiple vacuum suction cups.

[0008] The central control system is connected to the first robotic arm, the second robotic arm, the transfer suction cup assembly, and the switching assembly via an industrial Ethernet network. It performs motion trajectory planning for the first and second robotic arms, synchronous control of rotation and lifting of the switching assembly, vacuum status monitoring of the suction cup, and workstation status determination.

[0009] The present invention is further configured such that the rotation angle of the turntable of the transposition component is degrees, and the precise positioning is achieved through encoder feedback after the turntable has rotated.

[0010] The present invention is further configured such that the suction cups in the transfer suction cup assembly are made of flexible silicone material, the bottom of the suction cups are provided with a buffer pad layer, and each suction cup is independently connected to a vacuum pipeline and equipped with a solenoid valve and a pressure sensor.

[0011] The present invention is further configured such that the first robotic arm and the second robotic arm are six-axis articulated industrial robots of the same model and with the same motion parameters, and their respective arm spans cover the entire operating area between the battery supply station and the fuel cell stack assembly station.

[0012] The present invention is further configured such that the battery supply station is located within the working radius coverage area of ​​the first robotic arm, and the battery stack assembly station is located within the working radius coverage area of ​​the second robotic arm.

[0013] The present invention is further configured such that the battery stack assembly station is equipped with a pressure monitoring module, which is used to detect the contact pressure between battery cells during the stacking process and feed it back to the central control system.

[0014] The present invention is further configured such that the first robotic arm and the second robotic arm are composed of several joints, each joint being equipped with a drive unit and an encoder, and the drive unit and the encoder being connected to a central control system.

[0015] A method for using an automated device for a vanadium redox flow battery stack includes the following steps:

[0016] The central control system is activated to perform self-checks and zeroing operations on the first robotic arm, the second robotic arm, the transfer suction cup assembly, and the switching assembly; the status of each station is detected by pressure sensors and encoders to confirm that the battery supply station has materials and the stack assembly station is idle and meets the assembly conditions.

[0017] Under the control of the central control system, the first robotic arm moves to the battery supply station and adjusts its posture so that multiple suction cups in the transfer suction cup assembly are aligned with the surface of the battery cell to be picked up. The vacuum generator is started, each suction cup is independently powered and a negative pressure is established. The pressure sensor monitors the vacuum status in real time. After confirming that the gripping is successful, the battery cell is lifted.

[0018] After the central control system determines that the second robotic arm is in an idle state, it sends a rotation command to the switching component; the rotary driver drives the turntable to rotate smoothly, and the encoder provides real-time feedback of angle information to achieve precise positioning, so that the first robotic arm moves out of the working area and the second robotic arm enters the material picking preparation position.

[0019] The second robotic arm moves to the corresponding position above the turntable to receive the battery cells transferred by the first robotic arm, or picks them up directly from the turntable; then it accurately transfers the battery cells to the stack assembly station, and controls the stacking force under the closed-loop feedback of the pressure monitoring module, stacking the battery cells layer by layer to form a stack.

[0020] After each cell stacking is completed, the central control system determines whether the preset number of layers has been reached. If not, the first robotic arm continues to remove the next cell and repeat the stacking process. If the stacking is complete, the second robotic arm is controlled to exit and an assembly completion signal is triggered.

[0021] During operation, the central control system continuously monitors the suction cup vacuum level, robotic arm joint torque, positioning accuracy of the transfer component, and pressure monitoring module data. When any parameter exceeds the set threshold, the operation is immediately suspended, and the suction cup vacuum is safely released, an alarm is triggered, or an automatic reset is performed.

[0022] The present invention has the following beneficial effects:

[0023] 1. This invention employs a symmetrical layout of a first and second robotic arm, combined with a 180-degree rotating switching component, to achieve parallel and streamlined operation of the "material picking-transfer-stacking" process. While the first robotic arm picks up materials from the battery supply station, the second robotic arm can prepare to receive materials or perform stacking operations. Seamless switching between the two robotic arm stations is achieved through rapid and precise rotation of the turntable, avoiding the time loss associated with back-and-forth movement between material picking and assembly in traditional single-arm systems. This significantly shortens the single-operation cycle and improves overall production efficiency and equipment utilization.

[0024] 2. The entire process of handling, handover and stacking of battery cells in this invention is completed automatically by the system, which completely replaces the traditional manual handling and stacking operation. This not only significantly reduces the dependence on operators and labor intensity, but also avoids problems such as assembly deviation, scratches on battery surface or stacking misalignment caused by inconsistent human operation, thereby improving product consistency and yield.

[0025] Of course, any product implementing this invention does not necessarily need to achieve all of the advantages described above at the same time. Attached Figure Description

[0026] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below.

[0027] Figure 1 This is a schematic diagram of the overall structure of the automated device for a vanadium redox flow battery stack.

[0028] Figure 2 This is a schematic diagram of the transfer suction cup assembly of an automated device for vanadium redox flow battery stacks.

[0029] Figure 3 This is a schematic diagram of the vacuum generator and suction cup structure of an automated device for vanadium redox flow battery stacks.

[0030] Figure 4 This is a schematic diagram illustrating the usage process of an automated device for vanadium redox flow battery stacks.

[0031] The attached diagram lists the components represented by each number as follows:

[0032] 100. First robotic arm; 200. Second robotic arm; 300. Transfer suction cup assembly; 301. Suction cup bracket; 302. Suction cup; 303. Vacuum generator; 400. Transfer assembly; 401. Turntable; 402. Base; 403. Rotary actuator; 500. Central control system; 600. Battery supply station; 700. Battery stack assembly station; 701. Pressure monitoring module. Detailed Implementation

[0033] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention.

[0034] Example 1

[0035] Please see Figure 1-3This invention relates to an automated device for a vanadium redox flow battery stack, comprising a first robotic arm 100, a second robotic arm 200, a transfer suction cup assembly 300, a transposition assembly 400, and a central control system 500. The first robotic arm 100 and the second robotic arm 200 are symmetrically arranged and jointly mounted on a turntable 401 of the transposition assembly 400. A base 402 is mounted on the outside of the turntable 401, and the turntable 401 rotates with the base 402 via a rotary driver 403. The transfer suction cup assembly 300 is fixedly mounted on the end effectors of the first robotic arm 100 and the second robotic arm 200, and includes a suction cup bracket 301, multiple suction cups 302 disposed at the lower part of the suction cup bracket 301, and a vacuum generator 303 connected to the multiple vacuum suction cups 302.

[0036] The central control system 500 is connected to the first robotic arm 100, the second robotic arm 200, the transfer suction cup assembly 300, and the transposition assembly 400 via an industrial Ethernet, and performs motion trajectory planning for the first robotic arm 100 and the second robotic arm 200, synchronous control of rotation and lifting of the transposition assembly 400, vacuum status monitoring of the suction cup 302, and workstation status determination.

[0037] Specifically, the first robotic arm 100 and the second robotic arm 200 are six-axis articulated industrial robots of the same model and with identical motion parameters. Their respective arm spans cover the entire operating area between the battery supply station 600 and the battery stack assembly station 700. The battery supply station 600 is located within the working radius coverage area of ​​the first robotic arm 100, and the battery stack assembly station 700 is located within the working radius coverage area of ​​the second robotic arm 200. The battery stack assembly station 700 integrates a pressure monitoring module 701, which is used to detect the contact pressure between battery cells during the stacking process and feed it back to the central control system 500.

[0038] Furthermore, the turntable 401 of the transfer component 400 rotates at an angle of 180 degrees, and after the turntable 401 completes its rotation, precise positioning is achieved through encoder feedback; the first robotic arm 100 and the second robotic arm 200 are composed of several joints, each of which is equipped with a drive unit and an encoder, and the drive unit and encoder are connected to the central control system 500; the suction cup 302 in the transfer suction cup component 300 is made of flexible silicone material, the bottom of the suction cup 302 is provided with a buffer pad layer, and each suction cup 302 is independently connected to a vacuum pipeline and equipped with a solenoid valve and a pressure sensor.

[0039] The vanadium redox flow battery stack automation device provided in this embodiment is based on a "dual-arm collaboration + rotary transposition" technical solution, realizing efficient, stable, and automated operation of battery cells from supply to precision stacking assembly. The first robotic arm 100 and the second robotic arm 200 adopt a symmetrical layout and are jointly installed on the turntable 401 of the transposition component 400, forming a dual-station switching structure centered on the turntable 401. This allows the two robotic arms to interchange their working areas on the same platform through a 180-degree rotation of the turntable: when the first robotic arm 100 performs a material picking operation at the battery supply station 600, the second robotic arm 200 is in a standby or assembly state; after the turntable 401 rotates, the first robotic arm 100 exits the operating area, and the second robotic arm 200 immediately enters the battery supply station 600 to complete the receiving or direct picking action, thereby avoiding interference between the movement paths of the two arms and improving space utilization and operation continuity.

[0040] The turntable 401 in the transposition assembly 400 achieves precise rotational engagement with the base 402 via a rotary driver 403. The rotation angle is limited to 180 degrees, ensuring strict symmetrical switching between the two robotic arm positions. Simultaneously, the encoder provides real-time feedback on the rotation angle, ensuring positioning accuracy and preventing handover failure or collision risks due to angle deviation. The transfer suction cup assembly 300 is integrated at the ends of the two robotic arms, including a suction cup bracket 301, multiple flexible silicone suction cups 302, and a vacuum generator 303. The suction cups have a buffer pad at the bottom, which not only enhances the reliability of adsorption on the surface of the battery cell (usually smooth metal or composite material) but also effectively mitigates the impact force during the gripping process, preventing damage to the battery casing. Each suction cup is independently connected to a vacuum pipeline and equipped with a solenoid valve and pressure sensor, enabling independent monitoring and control of the status of each adsorption point, improving the fault tolerance and safety of the gripping process.

[0041] The central control system 500 is interconnected with all execution units via industrial Ethernet and is responsible for comprehensive tasks such as motion trajectory planning, multi-axis synchronous control, vacuum status monitoring, pressure feedback processing, and working condition judgment. In particular, the pressure monitoring module 701 integrated in the fuel cell stack assembly station 700 can provide real-time feedback on the contact pressure between individual units during the stacking process. This enables the central control system 500 to control the downward pressure of the second robotic arm 200 in a closed loop, ensuring the uniformity and structural stability of the fuel cell stack and avoiding problems such as increased internal resistance or seal failure caused by uneven pressure.

[0042] Example 2

[0043] Please see Figure 4 Based on the hardware of Implementation 1, the method of using the automated device for the all-vanadium redox flow battery stack includes the following steps:

[0044] The central control system 500 is started to perform self-inspection and zeroing operations on the first robotic arm 100, the second robotic arm 200, the transfer suction cup assembly 300, and the transfer assembly 400; the status of each station is detected by pressure sensors and encoders to confirm that the battery supply station 600 has materials and the battery stack assembly station 700 is idle and meets the assembly conditions.

[0045] Under the control of the central control system 500, the first robotic arm 100 moves to the battery supply station 600 and adjusts its posture so that multiple suction cups 302 in the transfer suction cup assembly 300 are aligned with the surface of the battery cell to be picked up; the vacuum generator 303 is started, each suction cup 302 is independently powered and establishes negative pressure, the pressure sensor monitors the vacuum status in real time, and after confirming that the gripping is successful, the battery cell is lifted up, which reflects the closed-loop gripping mechanism of "perception-execution-verification".

[0046] After the central control system 500 determines that the second robotic arm 200 is in an idle state, it sends a rotation command to the switching component 400; the rotary driver 403 drives the turntable 401 to rotate smoothly 180 degrees, and the encoder provides real-time feedback of angle information to achieve precise positioning, so that the first robotic arm 100 moves out of the working area and the second robotic arm 200 enters the material picking preparation position.

[0047] The second robotic arm 200 moves to the corresponding position above the turntable 401 to receive the battery cells transferred by the first robotic arm 100, or pick them up directly from the turntable 401; then it accurately transfers the battery cells to the stack assembly station 700, and controls the stacking force under the closed-loop feedback of the pressure monitoring module 701, and stacks the battery cells layer by layer to form a stack.

[0048] After each cell stacking is completed, the central control system 500 determines whether the preset number of layers has been reached. If not, the first robotic arm 100 continues to remove the next cell and repeat the stacking process. If the stacking is completed, the second robotic arm 200 is controlled to exit and an assembly completion signal is triggered.

[0049] During operation, the central control system 500 continuously monitors the vacuum level of the suction cup 302, the joint torque of the robotic arm, the positioning accuracy of the transfer component 400, and the data of the pressure monitoring module 701. When any parameter exceeds the set threshold, the operation is immediately suspended, and the vacuum of the suction cup 302 is safely released, an alarm is triggered, or an automatic reset is performed.

[0050] In the description of this specification, references to terms such as "an embodiment," "example," "specific example," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

Claims

1. An automated device and method for a vanadium redox flow battery stack, comprising a first robotic arm (100), a second robotic arm (200), a transfer suction cup assembly (300), a transposition assembly (400), and a central control system (500); characterized in that, The first robotic arm (100) and the second robotic arm (200) are symmetrically arranged and are jointly mounted on the turntable (401) of the transfer assembly (400). A base (402) is mounted on the outside of the turntable (401). The turntable (401) is rotatably engaged with the base (402) by a rotary driver (403). The transfer suction cup assembly (300) is fixedly mounted on the end effector of the first robotic arm (100) and the second robotic arm (200). It includes a suction cup bracket (301), a plurality of suction cups (302) disposed at the lower part of the suction cup bracket (301), and a vacuum generator (303) connected to the plurality of vacuum suction cups (302). The central control system (500) is connected to the first robotic arm (100), the second robotic arm (200), the transfer suction cup assembly (300), and the transposition assembly (400) via an industrial Ethernet network. It performs motion trajectory planning for the first robotic arm (100) and the second robotic arm (200), synchronous control of rotation and lifting of the transposition assembly (400), vacuum status monitoring of the suction cup (302), and workstation status determination.

2. The automated device and method for a vanadium redox flow battery stack according to claim 1, characterized in that, The rotation angle of the turntable (401) of the transposition component (400) is 180 degrees. After the turntable (401) has rotated, precise positioning is achieved through encoder feedback.

3. The automated device and method for a vanadium redox flow battery stack according to claim 1, characterized in that, The suction cups (302) in the transfer suction cup assembly (300) are made of flexible silicone material. The bottom of the suction cups (302) is provided with a buffer pad layer, and each suction cup (302) is independently connected to a vacuum pipeline and equipped with a solenoid valve and a pressure sensor.

4. The automated device and method for a vanadium redox flow battery stack according to claim 1, characterized in that, The first robotic arm (100) and the second robotic arm (200) are six-axis articulated industrial robots with the same model and motion parameters. Their arm spans cover the entire operating area between the battery supply station (600) and the stack assembly station (700).

5. The automated device and method for a vanadium redox flow battery stack according to claim 4, characterized in that, The battery supply station (600) is located within the working radius coverage area of ​​the first robotic arm (100), and the battery stack assembly station (700) is located within the working radius coverage area of ​​the second robotic arm (200).

6. The automated device and method for a vanadium redox flow battery stack according to claim 4, characterized in that, The battery stack assembly station (700) integrates a pressure monitoring module (701) to detect the contact pressure between battery cells during the stacking process and feed it back to the central control system (500).

7. The automated device and method for a vanadium redox flow battery stack according to claim 1, characterized in that, The first robotic arm (100) and the second robotic arm (200) are composed of several joints, each of which is equipped with a drive unit and an encoder, and the drive unit and the encoder are connected to the central control system (500).

8. A method of using an automated device for a vanadium redox flow battery stack based on any one of claims 1-7, comprising the following steps: The central control system (500) is started to perform self-checks and zeroing operations on the first robotic arm (100), the second robotic arm (200), the transfer suction cup assembly (300), and the transfer assembly (400); the status of each station is detected by pressure sensors and encoders to confirm that the battery supply station (600) has materials and the battery stack assembly station (700) is idle and meets the assembly conditions. The first robotic arm (100) moves to the battery supply station (600) under the control of the central control system (500), adjusts its posture so that multiple suction cups (302) in the transfer suction cup assembly (300) are aligned with the surface of the battery cell to be picked up; the vacuum generator (303) is started, each suction cup (302) is independently powered and establishes negative pressure, the pressure sensor monitors the vacuum status in real time, and the battery cell is lifted after confirming successful gripping; After the central control system (500) determines that the second robotic arm (200) is in an idle state, it sends a rotation command to the transfer component (400); The rotary driver (403) drives the turntable (401) to rotate smoothly by 180 degrees. The encoder provides real-time feedback of angle information to achieve precise positioning, so that the first robotic arm (100) moves out of the working area and the second robotic arm (200) enters the material preparation position. The second robotic arm (200) moves to the corresponding position above the turntable (401) to receive the battery cells transferred by the first robotic arm (100), or pick them up directly from the turntable (401); then it accurately transfers the battery cells to the stack assembly station (700), and under the closed-loop feedback of the pressure monitoring module (701), it controls the stacking force and stacks the battery cells layer by layer to form a stack. After each individual stack is completed, the central control system (500) determines whether the preset number of layers has been reached; If not completed, the first robotic arm (100) will continue to remove the next battery cell and repeat the stacking process; if completed, the second robotic arm (200) will be controlled to exit and trigger the assembly completion signal. During operation, the central control system (500) continuously monitors the vacuum level of the suction cup (302), the joint torque of the robotic arm, the positioning accuracy of the transfer component (400), and the data of the pressure monitoring module (701). When any parameter exceeds the set threshold, the operation is immediately suspended, and the vacuum of the suction cup (302) is safely released, an alarm is triggered, or an automatic reset is performed.

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