Automatic module boxing system and method for CTP-S battery pack

Abstract

The invention relates to the technical field of CTP-S battery module assembly, in particular to an automatic module boxing system and method for a CTP-S battery pack. Comprising a line body integration unit, a code scanning mechanism, a material taking mechanism, a carrying truss, a PACK jacking positioning unit, a collaborative robot unit and a control system. The control system is in communication connection with the carrying truss, the material taking mechanism, the collaborative robot unit, the line body integration unit, the code scanning mechanism and the PACK jacking positioning unit. The control system obtains position compensation data generated after a plurality of preset positions in the battery pack box body are subjected to visual positioning by a visual camera of the collaborative robot unit; the control system controls the carrying truss and the material taking mechanism to act cooperatively according to the position compensation data, grabbing and placing operation is executed through the material taking mechanism, and grabbing of the module from the line body integration unit and box entering of the battery pack box on the carrying trolley are achieved. And the effects of high precision, no damage, high efficiency, wide compatibility and full-automatic assembly of the heavy CTP-S battery module are achieved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of CTP-S battery module assembly, and particularly relates to a module automatic boxing system and method for a CTP-S battery pack. BACKGROUND

[0002] With the rapid development of the new energy automobile industry, the production efficiency, assembly precision and process quality consistency of the power battery pack (PACK) are extremely demanding. The CTP (Cell to Pack) technology is widely used because it can significantly improve the volume utilization rate and energy density, but the module has the characteristics of large size and heavy weight (up to 120 kg). How to assemble it to the battery pack lower box body with high precision, zero damage and cleanliness becomes the core bottleneck restricting the production line rhythm and product reliability. At present, the industry generally adopts an automatic solution based on a lead screw lifting mechanism, and a vision system is used for auxiliary positioning, but this technical system faces systematic challenges in actual application. First, in the heavy load high frequency working condition, the lead screw mechanism has a risk of wear and tear, and the vision system has a single function, which is only used for rough positioning or code scanning, and cannot realize high-precision global pre-calibration and final state re-inspection before boxing, resulting in that the positioning accuracy is disturbed, and the risk of attaching insects and other foreign matters after gluing is difficult to be effectively intercepted. Secondly, the traditional grabbing and placing process lacks precise closed-loop control of clamping force and soft adaptive ability to assembly deviation, which easily causes damage to the battery cell or assembly jam. In addition, the equipment lacks flexibility when facing modules with a wide size range (such as length 150-1200 mm, width 150-700 mm), and the type change adjustment takes time, and the overall structure is large and inconvenient to maintain, which is difficult to meet the intelligent manufacturing requirements of high efficiency, flexibility and reliability. Therefore, an innovative automatic assembly system is urgently needed to systematically solve the above outstanding problems in precision, cleanliness, safety, flexibility and efficiency. SUMMARY

[0003] The present application aims to provide a module automatic boxing system and method for a CTP-S battery pack to solve the above problems.

[0004] In order to achieve the above purpose, the technical scheme adopted by the present application is as follows: a module automatic boxing system for a CTP-S battery pack comprises a component transportation mechanism, a line body integrated unit, a code scanning mechanism, a material taking mechanism, a carrying truss, a PACK jacking positioning unit, a collaborative robot unit and a control system. The line body integrated unit is used for receiving and conveying the component transportation mechanism carrying the battery module; The code scanning mechanism is arranged above or on the side of the line body integrated unit, and is used for identifying the identity and detecting the shape of the battery module on the component transportation mechanism. The carrying truss is provided with a beam extending along the X axis and a driving mechanism, and a sliding seat moving along the Y axis is installed on the beam; The material taking gripper is installed on the sliding seat and comprises a Z1-axis electric cylinder connected with the sliding seat, a connecting frame installed on the movable end of the Z1-axis electric cylinder, a Z2-axis electric cylinder installed on the connecting frame, and an end clamping mechanism and a side clamping mechanism; The end clamping mechanism and the side clamping mechanism are both provided with a pressure sensor, and the movable end of the Z-axis electric cylinder is provided with a vacuum chuck assembly; The collaborative robot unit is arranged on the side of the carrying truss, and the execution end thereof is provided with a double-vision camera; The PACK jacking positioning unit is used for positioning the carrying trolley carrying the battery pack box; The control system is in communication connection with the carrying truss, the material taking mechanism, the collaborative robot unit, the line body integration unit, the code scanning mechanism and the PACK jacking positioning unit; The control system obtains position compensation data generated after the vision camera of the collaborative robot unit visually positions a plurality of preset positions in the battery pack box; the control system controls the carrying truss and the material taking mechanism to act cooperatively according to the position compensation data, and performs grabbing and placing operations through the material taking mechanism, so as to realize grabbing of the module from the line body integration unit and entering into the battery pack box on the carrying trolley.

[0005] Further, the end clamping mechanism and the side clamping mechanism are both connected with a servo driving unit; The servo driving unit comprises a servo motor, a ball screw driven by the servo motor, and a magnetic scale for detecting the actual displacement of the screw nut seat or the clamping jaw; The signals of the pressure sensor and the magnetic scale are fed back to the control system, the control system performs PID operation based on the difference between the target clamping force and the feedback signal of the pressure sensor, outputs a control quantity to the servo motor to constitute a closed-loop control of the clamping force, and at the same time, based on the difference between the target clamping displacement and the feedback signal of the magnetic scale, the movement of the servo motor is protected from overtravel.

[0006] Further, the servo driving unit of the end clamping mechanism drives the clamping jaw thereof to move along the length direction of the module, and the single-side effective stroke is not less than 400 mm to be compatible with modules with a length in the range of 150 mm to 1200 mm; The servo driving unit of the side clamping mechanism drives the clamping jaw thereof to move along the width direction of the module, and the single-side effective stroke is not less than 220 mm to be compatible with modules with a width in the range of 150 mm to 700 mm.

[0007] Further, the material taking mechanism further comprises a quick-change docking mechanism for connecting and quickly replacing different specifications of clamps; The quick-change docking mechanism comprises a connecting base mounted on the output side of the servo drive unit, a docking part mounted on the clamp side, and a pneumatic latch assembly for locking the docking part on the connecting base; The connecting base is provided with a positioning pin and an in-place sensor for detecting whether the docking part is in place, and the pneumatic latch assembly and the in-place sensor are both in communication connection with the control system.

[0008] Further, the clamp jaw of the end clamp mechanism is integrated with a first pressure sensor for detecting the contact pressure of the module end face; the clamp jaw of the side clamp mechanism is integrated with a second pressure sensor for detecting the contact pressure of the module side face; during the clamping process, when the pressure value detected by the first pressure sensor reaches a first preset threshold value, and / or the pressure value detected by the second pressure sensor reaches a second preset threshold value, the control system controls the corresponding servo drive unit to stop feeding and keep.

[0009] Further, a gripper vision unit is provided on the material taking mechanism; the gripper vision unit comprises a camera, a light source for providing illumination for the camera, and a lifting drive module for driving the camera to move in the vertical direction; the lifting drive module is a servo motor driven lead screw sliding table or a gas cylinder driven linear sliding table; after the material taking mechanism is positioned above the grabbing station, the control system controls the camera to descend and visually position the module on the tray to generate grabbing position compensation data; before entering the box, the control system controls the camera to descend and visually position the target placement site in the box to generate fine adjustment data of the entering box position.

[0010] Further, the vacuum chuck assembly is installed on the movable end of the Z-axis electric cylinder through a zero-point quick-change disc integrated with multiple vacuum paths; the zero-point quick-change disc is connected with an independent vacuum control system, which comprises at least three independent vacuum circuits, each of which is provided with an independent vacuum generator, a vacuum on-off valve and a vacuum degree sensor; the control system respectively monitors the vacuum degree of each vacuum circuit, and alarms or executes a safety process when the vacuum degree of any circuit is lower than a set threshold value.

[0011] Further, the crossbeam of the carrying truss adopts a single heavy-load linear guide rail as a load-bearing and guiding mechanism, and the Y-axis sliding seat straddles the single heavy-load linear guide rail through a sliding block; the crossbeam, the Y-axis sliding seat and their driving mechanisms are configured as a sunken mounting structure, and the running plane of the Y-axis sliding seat is lower than the top surface of the crossbeam.

[0012] Further, the control system is configured to perform the following box-in action: control the material taking mechanism to move the module above the target position of the box, control the Z-axis electric cylinder to lower so that the bottom of the module enters the opening of the box; control the servo drive units of the end clamp mechanism and the side clamp mechanism to act, so that the clamping jaws are loosened by a set distance; control the positioning pin cylinder and the brake cylinder provided on the material taking mechanism to release, so that the material taking mechanism is in a floating state in the horizontal plane; control the Z-axis electric cylinder to drive the vacuum suction disc assembly and the adsorbed module to complete the final fine lowering box-in action.

[0013] A module automatic box-in method for CTPS battery packs, the method comprising the following steps: S1. Module feeding and identification: control the linear body integrated unit to transport the component carrying mechanism carrying the battery module to the grabbing station and perform jacking positioning; control the code scanning mechanism to visually scan the battery module on the component carrying mechanism to identify the module code, positive and negative poles, and outer shape size; S2. Box feeding and positioning: control the PACK jacking positioning unit to jacking position the carrying trolley carrying the battery pack box; S3. Box visual positioning compensation: control the collaborative robot unit to move the visual camera at the end thereof to take pictures of the marker points of a plurality of preset box-in stations in the battery pack box, calculate the position and angle deviation of each station, and generate position compensation data; S4. Module grabbing: control the carrying truss to drive the material taking gripper to move above the grabbing station; control the Z1-axis electric cylinder to lower to a preset height; first control the vacuum suction disc assembly to adsorb the module; then control the Z1-axis electric cylinder to lift the module to make it separate from the tray; and then control the end clamp mechanism and the side clamp mechanism to close under servo drive to clamp the module, and the pressure sensor feeds back the clamping force in real time; S5. Module box-in: according to the position compensation data, control the carrying truss to drive the material taking mechanism carrying the module to move above the target box-in station; control the Z-axis electric cylinder to lower so that the bottom of the module enters the opening of the box; control the clamping jaws of the end clamp mechanism and the side clamp mechanism to loosen by a preset distance; control the positioning pin cylinder and the brake cylinder on the material taking mechanism to release; control the Z-axis electric cylinder to drive the vacuum suction disc assembly and the adsorbed module to complete fine lowering, and after the module is placed at a predetermined position in the box, release the vacuum; S6. Circulation and flow: control the material taking mechanism to reset, the carrying trolley flows to the next station, and repeat steps S1 to S5 until the box-in of all modules is completed.

[0014] Compared with the prior art, the present application has the following beneficial effects: Firstly, high-precision assembly and whole-process quality control of heavy modules are realized. In view of the problems of positioning accuracy affected by vibration interference and lack of final inspection before entering the box in the traditional scheme, a double-vision system is integrated by a collaborative robot unit: the first group of large field of view cameras quickly and accurately globally pre-calibrate the battery pack box, providing a high-precision position reference for the handling system; the second group of high-resolution small field of view cameras re-inspect the ultimate state of the glue area of the lower box before the module enters the box, which can effectively identify foreign matter such as mosquito attachment, and eliminate the risk of pollutants being brought into the battery pack from the source. The double-vision system combined with the end precision check of the material taking gripper forms a multi-level and closed-loop quality guidance and guarantee system of "global positioning-end review-state re-inspection", which not only ensures the positioning accuracy and repeatability of the heavy module entering the box, but also realizes the whole-process and traceable quality control from positioning accuracy to assembly cleanliness.

[0015] Secondly, the safety of the assembly process and the protection of the product are significantly improved. Through the force-position double closed-loop control of the end clamping mechanism and the side clamping mechanism, the accurate management of clamping force and overload protection are realized, which fundamentally eliminates the risk of cell damage. The soft entry control logic (rough positioning-loose clamping jaw-release floating-precision descent) enables the 120kg heavy module to be guided into the box in an adaptive state, effectively avoiding the jamming and scratching caused by box tolerance or cumulative error, and ensuring the safety of the assembly process and the integrity of the product at the physical level.

[0016] Thirdly, excellent production line flexibility and production efficiency are provided. The material taking gripper can flexibly compatible with multiple specifications of modules with length of 150-1200mm and width of 150-700mm, thanks to its wide range of effective travel design and quick change docking mechanism, which greatly shortens the product changeover time. Combined with the compact settlement type design of the handling truss and the process optimization of three entry workstations operating in parallel, the whole system can meet the high efficiency production requirement of 150 seconds beat in limited space.

[0017] Finally, the equipment structure is optimized, and the maintainability and reliability are enhanced. The handling truss adopts a single heavy load linear guide as the core bearing and guiding mechanism, which is combined with the settlement type installation to significantly reduce the overall height and gravity center of the equipment, facilitating installation and maintenance in existing factory buildings. The vacuum suction system is connected through a zero-point quick change disc and equipped with at least 3 independently monitored vacuum circuits, combined with the quick change interface design of the key function modules, which greatly improves the stability and maintainability of the system during long-term operation, and reduces the total life cycle operating cost. BRIEF DESCRIPTION OF DRAWINGS

[0018] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the following will briefly introduce the drawings needed to be used in the embodiments or prior art description. Obviously, the drawings described below are only some embodiments of the present application, and other drawings can also be obtained by those skilled in the art without creative effort on the basis of these drawings.

[0019] Figure 1 A structure top view of a module automatic boxing system for CTP-S battery packs according to an embodiment of the present application; Figure 2 A structure perspective view of a module automatic boxing system for CTP-S battery packs according to an embodiment of the present application without guardrails; Figure 3 A structure perspective view of a module automatic boxing system for CTP-S battery packs according to an embodiment of the present application with guardrails; Figure 4 A perspective view of a material taking mechanism according to an embodiment of the present application; Figure 5 Another perspective view of a material taking mechanism according to an embodiment of the present application from another angle.

[0020] Reference signs: 1, component shipping mechanism; 2, line body integrated unit; 3, code scanning mechanism; 4, material taking mechanism; 4-1, Z1-axis electric cylinder; 4-2, Z2-axis electric cylinder; 4-3, end clamping mechanism; 4-4, side clamping mechanism; 4-5, quick-change docking mechanism; 4-6, gripper vision unit; 4-7, zero quick-change disc; 5, carrying truss; 6, PACK jacking positioning unit; 7, carrying trolley; 8, collaborative robot unit. DETAILED DESCRIPTION

[0021] The technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only some embodiments of the present application, not all embodiments.

[0022] In the description of the present application, it should be noted that the orientation or position relationship indicated by "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer" and the like is based on the orientation or position relationship shown in the drawings, and is only for the convenience of describing the present application and simplifying the description, and therefore cannot be understood as indicating or implying that the device or element must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as limiting the present application.

[0023] A module automatic boxing system for CTP-S battery packs, as shown in Figures 1-5As shown, it comprises a component conveying mechanism 1, a line body integration unit 2, a code scanning mechanism 3, a material taking mechanism 4, a carrying truss 5, a PACK jacking positioning unit 6, a collaborative robot unit 8 and a control system; The line body integration unit 2 is used for receiving and conveying the component conveying mechanism 1 carrying the battery module; The code scanning mechanism 3 is arranged above or on the side of the line body integration unit 2, and is used for identity recognition and appearance detection of the battery module on the component conveying mechanism 1; The carrying truss 5 is provided with a cross beam extending along the X axis and a driving mechanism, and the cross beam is provided with a sliding seat moving along the Y axis; The material taking gripper 4 is installed on the sliding seat and comprises a Z1-axis electric cylinder 4-1 connected with the sliding seat, a connecting frame installed on the movable end of the Z1-axis electric cylinder 4-1, a Z2-axis electric cylinder 4-2 installed on the connecting frame, an end clamping mechanism 4-3 and a side clamping mechanism 4-4; The end clamping mechanism 4-3 and the side clamping mechanism 4-4 are both provided with a pressure sensor, and the movable end of the Z2-axis electric cylinder 4-2 is provided with a vacuum suction cup assembly; The collaborative robot unit 8 is arranged on the side of the carrying truss 5, and the execution end thereof is provided with a double-vision camera; The PACK jacking positioning unit 6 is used for positioning the carrying trolley 7 carrying the battery pack box body; The control system is in communication connection with the carrying truss 5, the material taking mechanism 4, the collaborative robot unit 8, the line body integration unit 2, the code scanning mechanism 3 and the PACK jacking positioning unit 6; The control system obtains position compensation data generated after the vision camera of the collaborative robot unit 8 visually positions a plurality of preset positions in the battery pack box body; the control system controls the carrying truss 5 and the material taking mechanism 4 to cooperate according to the position compensation data, and performs grabbing and placing operation through the material taking mechanism 4, so as to realize grabbing of the module from the line body integration unit 2 and in-boxing into the battery pack box body on the carrying trolley 7.

[0024] Specifically, through the overall layout of the system including component shipping mechanism 1, line body integration unit 2, code scanning mechanism 3, material taking mechanism 4, carrying truss 5, PACK jacking positioning unit 6 and collaborative robot unit 8, each unit is coordinated and controlled by a unified control system. The component shipping mechanism 1 is used to carry the battery module to be assembled. The line body integration unit 2 is usually a section of conveying line body, which receives the component shipping mechanism 1 from the previous process and accurately delivers it to the preset grabbing station. This unit integrates jacking and positioning mechanism, which can lift and lock the tray after it is positioned, ensuring that the module is in a known fixed position. The code scanning mechanism 3 is installed on the upper frame of the line body integration unit 2, which contains multiple industrial cameras and light sources. When the component shipping mechanism 1 is positioned at the grabbing station, the code scanning mechanism 3 scans all the modules on the tray synchronously, reads the two-dimensional code information on the module surface, and judges the polarity direction and profile size of the module pole through visual image, completing the initial collection and verification of module information. The carrying truss 5 is the main motion mechanism of the system, whose crossbeam extends along the X-axis direction. The crossbeam is installed with a slide that can move along the Y-axis direction. The driving mechanism usually includes a servo motor, a speed reducer, a gear and a rack or a lead screw module. The material taking mechanism 4 is fixed on the slide through a mounting plate, so as to realize accurate movement in the XY plane. The material taking mechanism 4 is the core component for performing grabbing and placing operations. Its main body is a multi-axis mechanism, and the uppermost end is a Z1-axis electric cylinder 4-1, whose cylinder body is connected with the slide of the carrying truss 5. The lower end of the push rod of the Z1-axis electric cylinder 4-1 is installed with a Z2-axis electric cylinder 4-2. At the lower end of the push rod of the Z2-axis electric cylinder 4-2, an end clamping mechanism 4-3 and a side clamping mechanism 4-4 are installed. The end clamping mechanism 4-3 includes a pair of clamping jaws that can move towards each other, used for clamping the length direction of the module. The side clamping mechanism 4-4 also includes a pair of clamping jaws, used for clamping the width direction of the module. Both sets of clamping mechanism are integrated with pressure sensors for real-time monitoring of clamping force. At the center of the end clamping mechanism 4-3 and the side clamping mechanism 4-4, the push rod of the Z2-axis electric cylinder 4-2 is also installed with a set of vacuum suction cup assembly, used for absorbing the upper surface of the module from above, grabbing the module through negative pressure adsorption force, and first fixing the module for grabbing, so as to facilitate the end clamping mechanism 4-3 and the side clamping mechanism 4-4 to further clamp and grab the module. The collaborative robot unit 8 is independently arranged in the side space of the carrying truss 5, which is usually a six-axis collaborative robot, and the end flange is installed with a high-precision two-dimensional vision camera. The PACK jacking positioning unit 6 is located within the working range of the collaborative robot unit 8, used for accurately jacking and positioning the carrying trolley 7 loaded with the battery pack lower box (i.e. PACK pack), and eliminating the position error caused by AGV conveying.The control system is in communication connection with all the above-mentioned execution units and sensors, and its working process is as follows: the control system first schedules the line body integration unit 2 and the code scanning mechanism 3 to complete the feeding and information identification of the module, at the same time, the control PACK jacking positioning unit 6 positions the carrying trolley 7, then the control collaborative robot unit 8 moves, so that the end camera traverses each module preset installation position in the battery pack box body, and takes a photo of the positioning mark point of each installation position, calculates the deviation of each position relative to the theoretical coordinates through image processing, and generates a set of position compensation data. Based on the compensation data, the control system plans the path of the carrying gantry 5 and the taking mechanism 4. The taking mechanism 4 first moves above the positioned component transfer mechanism 1, the Z1 axis electric cylinder 4-1 descends, and the taking gripper 4 first moves above the positioned component transfer mechanism 1, the Z1 axis electric cylinder 4-1 descends to the preset height. Then, the control system first controls the Z2 axis electric cylinder 4-2 to drive the vacuum suction cup assembly to descend, so that it is in contact with the upper surface of the module and starts vacuum suction, and the module is preliminarily sucked and lifted. After confirming that the vacuum suction is effective, the end clamping mechanism 4-3 and the side clamping mechanism 4-4 are controlled to close towards each other under the servo drive, and the pressure sensor feedbacks in real time to ensure that the clamping force is within the safe range. Through the combined action of vacuum suction and mechanical clamping, the module is stably gripped. Then, the Z1 axis electric cylinder 4-1 rises, the carrying gantry 5 drives the taking mechanism 4 and the module to move above the target work position of the battery pack box body.

[0025] When entering the box, the control system controls the Z1-axis electric cylinder 4-1 to descend so that the bottom of the mold group enters the opening of the box. Subsequently, the control end clamp and the side clamp mechanism are loosened by a certain distance under the action of their own driving units, so that a small gap is generated between the clamping jaw and the mold group. At the same time, the horizontal floating mechanism is released. Finally, the control system only drives the Z2-axis electric cylinder 4-2 to fine descend, and the mold group is placed in the final target position by using the shorter stroke and higher control precision of the Z2-axis electric cylinder 4-2. After the placement is completed, the vacuum is released, and the Z-axis is reset in turn, thereby completing the entering box cycle of a mold group. The technical scheme of the present application first solves the problem of high-precision entering box of a heavy mold group by using a multi-sensor cooperative positioning and execution system composed of a carrying truss 5, a collaborative robot unit 8 and a taking mechanism 4. The collaborative robot unit 8 carries a camera to perform global pre-scanning and generate full-box position compensation data, and the taking mechanism 4 is responsible for the final execution, which decouples the visual positioning and heavy carrying in space and time, avoids the vibration interference problem caused by the movement of the visual camera with the heavy gripper in the traditional scheme, and thus realizes the entering box positioning precision of the 120kg-level mold group. Secondly, the taking mechanism 4 adopts a double-layer electric cylinder design of the Z1-axis electric cylinder 4-1 and the Z2-axis electric cylinder 4-2, and combines the composite gripping mode of the end clamp mechanism 4-3, the side clamp mechanism 4-4 and the vacuum chuck assembly, and the soft control strategy of releasing the horizontal degree of freedom in the entering box stage, thereby significantly improving the reliability and safety of the operation. The Z1-axis electric cylinder 4-1 is responsible for large-stroke rapid lifting, and its service life and reliability are better than those of the traditional ball screw. The Z2-axis electric cylinder 4-2 is responsible for the end fine press-fitting and placement. In the final stage of entering the box, the horizontal degree of freedom of the gripper is released, and only the Z2-axis electric cylinder 4-2 completes the last stroke, so that the mold group weighing 120kg can be adaptively guided into the box in a floating state, thereby effectively eliminating the risk of jamming and scratching caused by the tolerances of the box or the mold group. The pressure sensors on the end clamp and the side clamp realize closed-loop control of the clamping force, thereby preventing overpressure damage to the electric core. Furthermore, the system completes the initial verification of the mold group identity and polarity at the entrance through the code scanning mechanism 3, and the vision of the collaborative robot unit 8 records the box state before entering the box, such as the box interior image after gluing and before entering the box, thereby realizing the key quality data traceability in the whole production process and meeting the harsh requirements of high-end battery manufacturing on process rigor and traceability. Finally, the carrying truss 5 adopts a single heavy-load guide rail beam and a sinking type design, which greatly reduces the horizontal space occupation and overall height of the equipment, and is convenient for layout, installation and later maintenance in the existing factory building.

[0026] As a preferred embodiment of the above-mentioned embodiment, as shown in Figures 1-5 The end clamp mechanism 4-3 and the side clamp mechanism 4-4 are connected with servo driving units; The servo driving unit comprises a servo motor, a ball screw driven by the servo motor and a magnetic scale for detecting the actual displacement of the screw nut seat or the clamping jaw; The signal of the pressure sensor and the signal of the magnetic grating scale are fed back to the control system, the control system performs PID operation based on the difference between the target clamping force and the feedback signal of the pressure sensor, and outputs a control amount to the servo motor to constitute a closed-loop control of the clamping force; meanwhile, the movement of the servo motor is protected from overtravel based on the difference between the target clamping displacement and the feedback signal of the magnetic grating scale.

[0027] Specifically, the side clamping mechanism 4-4 includes a side clamping plate for clamping the mold from both sides; the end clamping mechanism 4-3 includes an end clamping plate for clamping the mold from both ends; the material taking mechanism can also include a bottom holding mechanism such as a bottom rod for supporting the bottom of the mold during the carrying process to prevent falling; the core driving components of the end clamping mechanism 4-3 and the side clamping mechanism 4-4 are servo driving units, each of which mainly consists of: a servo motor, a speed reducer directly connected to the output shaft of the servo motor, and a set of precision ball screw pair driven by the speed reducer. The nut seat of the ball screw is directly connected to the corresponding clamping jaw through a connecting piece, so as to convert the rotary motion of the servo motor into the precise linear opening and closing motion of the clamping jaw. In order to realize high-precision control of the position and clamping force of the clamping jaw, two kinds of key sensors are introduced into the system. First, a set of magnetic grating scales are installed in parallel on the linear motion path of each servo driving unit, the reading head of the magnetic grating scale moves synchronously with the clamping jaw or the nut seat, which can detect the absolute position of the clamping jaw in real time and continuously, and the detection accuracy can reach microns, which constitutes the core of the position closed-loop detection. Secondly, as mentioned above, a patch type pressure sensor is integrated on the contact surface of the clamping jaw of the end clamping mechanism 4-3 and the side clamping mechanism 4-4, which is used to directly measure the normal pressure between the clamping surface and the mold. A special double closed-loop control algorithm is configured in the software of the control system. The control logic specific implementation process is as follows: when the control system issues a clamping instruction, the servo motor drives the clamping jaw to move towards the mold. During this process, the control system first reads the real-time position feedback of the magnetic grating scale to ensure that the movement is carried out according to the predetermined trajectory, and has a hard limit and a soft limit to prevent overtravel collision, which is the overtravel protection function based on the position loop. When the clamping jaw contacts the mold, the pressure sensor begins to generate a feedback signal. The control algorithm immediately switches to a force control dominated mode. The system compares the preset target clamping force, for example, the target value of the end clamping mechanism is adjustable within the range of 300 to 20000 Newton, with the real-time feedback value of the pressure sensor, and calculates the difference. Based on this difference, the system performs real-time operation through proportional-integral-derivative algorithm, dynamically adjusts the control amount (usually torque or speed instruction) output to the servo motor, so that the actual clamping force quickly and smoothly approaches and stabilizes around the target value, forming a complete clamping force closed-loop control loop.

[0028] As a preferred embodiment of the above embodiment, the end clamping mechanism 4-3 and the side clamping mechanism 4-4 are respectively provided with a plurality of clamping jaws, and the plurality of clamping jaws are arranged in a staggered manner. Figures 1-5As shown, the servo drive unit of the end clamp mechanism 4-3 drives its clamping jaws to move along the length direction of the module, with a single-side effective stroke of no less than 400 mm to accommodate modules with a length in the range of 150 mm to 1200 mm; The servo drive unit of the side clamp mechanism 4-4 drives its clamping jaws to move along the width direction of the module, with a single-side effective stroke of no less than 220 mm to accommodate modules with a width in the range of 150 mm to 700 mm.

[0029] Specifically, the servo drive unit of the end clamp mechanism 4-3 is configured to drive its pair of clamping jaws to move towards or away from each other along the length direction of the battery module. The design of the drive unit ensures that the one-way effective movement stroke of each side clamping jaw from the center zero position outward is no less than 400 mm. Here, the "effective stroke" refers to the movement distance within the range allowed by the mechanical structure and accurately feedbackable by the position detection system (such as a magnetic scale), which can stably and accurately reach and exert the rated clamping force. Based on this design, when the two side clamping jaws move towards each other synchronously, the minimum clamping length they can adapt to is about 150 mm, and the maximum clamping length can reach 1200 mm, thereby covering the length size spectrum of the current mainstream CTP-S battery modules. The servo drive unit of the side clamp mechanism 4-4 is configured to drive its pair of clamping jaws to move along the width direction of the battery module. Similarly, the one-way effective stroke of each side clamping jaw is designed to be no less than 220 mm. Accordingly, the module width that the mechanism can adapt to is minimally about 150 mm and maximally about 700 mm, which fully considers the diversity requirements of different battery pack designs on the module width size. This embodiment first accurately quantifies and matches the effective strokes of the end clamp mechanism 4-3 and the side clamp mechanism 4-4, thereby fundamentally guaranteeing the physical compatibility of the taking mechanism 4 to most CTP-S specification modules on the market in terms of mechanical movement capability. As a preferred embodiment of the above embodiment, as shown in Figures 1-5 The taking mechanism 4 further includes a quick-change docking mechanism 4-5 for connecting and quickly replacing different specification clamping jaws; The quick-change docking mechanism 4-5 includes a connection base installed on the output side of the servo drive unit, a docking part installed on the clamping jaw side, and a pneumatic latch assembly for locking the docking part on the connection base; The connection base is provided with a positioning pin and a position sensor for detecting whether the docking part is in place, and the pneumatic latch assembly and the position sensor are both in communication connection with the control system.

[0030] Specifically, the quick-change docking mechanism 4-5 is mainly composed of three parts. The first part is a connecting base, which is fixedly installed on the final output end of the servo drive unit, such as the nut seat of a ball screw or a direct drive plate. The second part is a docking part, which is fixedly connected with the jaw body. The third part is a pneumatic latch assembly, the cylinder of which is installed on the connecting base. On the mating surface of the connecting base and the docking part, a precise mechanical positioning structure is provided. Specifically, at least two high-precision hardened positioning pins are installed on the connecting base, and matching pin holes are processed on the docking part. When the jaw needs to be replaced, the operator or auxiliary equipment moves the jaw together with the docking part to a position close to the connecting base, preliminarily aligns through the guide structure, and then the positioning pins are guided into the pin holes, thereby ensuring that the docking part is accurately and repeatedly positioned on the connecting base. After the docking part reaches the predetermined position, the pneumatic latch assembly acts under the instruction of the control system. The internal latch is driven by the air cylinder to extend and insert into the corresponding lock hole on the docking part, thereby rigidly locking the docking part and the connecting base. To ensure the reliability of the locking state, a position sensor, such as a photoelectric sensor or an inductive proximity switch, is also installed on the connecting base to detect whether the docking part is completely and properly attached. The above-mentioned pneumatic latch assembly and the position sensor are both connected with the control system through an electrical interface. The logic design of the control system is to first control the pneumatic latch to retract for unlocking after receiving the instruction to replace the jaw. When installing a new jaw, the system continuously reads the signal of the position sensor, and as soon as the docking part is detected to be in place, the pneumatic latch is triggered to extend and lock, and the locking state signal is verified again, completing a safe and fast replacement process. This greatly improves the utilization rate of the equipment and the production flexibility. Secondly, the sensor detection and automatic control logic are deeply integrated to form a closed-loop operation confirmation process, which eliminates the safety accidents or equipment damage that may be caused by starting the equipment without reliable fixation of the jaw.

[0031] In summary, the specific implementation of the quick-change docking mechanism 4-5 effectively solves the general problem of quick, safe and accurate replacement of tooling fixtures in automated production lines through the combination of precise mechanical design, pneumatic execution and automatic detection control. It enables the material taking mechanism 4 described in the present application to flexibly adapt to new specifications that may appear in the future, prolongs the technical life cycle of the equipment, and reduces the secondary investment cost caused by product iteration. The quick-change docking mechanism can realize quick adjustment and replacement of the jaw position through the cooperation of the waist-shaped hole and the bolt.

[0032] As a preferred embodiment of the above-mentioned embodiment, as Figures 1-5As shown, the first pressure sensor for detecting the contact pressure of the end face of the mold module is integrated on the clamping jaw of the end clamping mechanism 4-3; the second pressure sensor for detecting the contact pressure of the side face of the mold module is integrated on the clamping jaw of the side clamping mechanism 4-4; during the clamping process, when the pressure value detected by the first pressure sensor reaches the first preset threshold value, and / or the pressure value detected by the second pressure sensor reaches the second preset threshold value, the control system controls the corresponding servo drive unit to stop feeding and keep.

[0033] Specifically, the first pressure sensor is installed on the inner side of the clamping jaw of the end clamping mechanism 4-3, i.e. the clamping surface directly contacting the end face of the mold module. The sensor is packaged or firmly installed in the clamping jaw body structure, and the sensing surface is flush or slightly protruding from the clamping surface, so as to ensure that the normal pressure applied by the clamping jaw to the end face of the mold module can be accurately and directly detected. The second pressure sensor is installed on the inner side of the clamping jaw of the side clamping mechanism 4-4 in the same way, for directly measuring the clamping force on the side face of the mold module. The control system has preset key pressure threshold parameters. For the first pressure sensor, the first preset threshold value triggered is a settable value, which ranges from 0 to 20000N. For the second pressure sensor, the corresponding second preset threshold value is set according to the pressure bearing capacity of the side face structure of the mold module. The control process is as follows: during the process of closing the clamping jaw driven by the servo drive unit to clamp the mold module, the control system synchronously reads the feedback signals of the first pressure sensor and the second pressure sensor in real time. The system will continuously compare the currently detected pressure value with the respective preset threshold value. Once it is judged that the reading of the first pressure sensor reaches or exceeds the first preset threshold value, and / or the reading of the second pressure sensor reaches or exceeds the second preset threshold value, the control system will immediately issue a stop command to the servo motor of the corresponding servo drive unit, so as to stop the feeding motion and enter the position keeping mode, thereby stabilizing the clamping force at the current level. As a preferred embodiment of the above embodiment, as shown, Figures 1-5 As shown, the visual unit 4-6 is arranged on the taking mechanism 4; the visual unit 4-6 includes a camera, a light source for providing illumination for the camera, and a lifting drive module for driving the camera to move in the vertical direction; the lifting drive module is a screw rod sliding table driven by a servo motor or a linear sliding table driven by a gas cylinder; after the taking mechanism 4 is positioned above the grabbing position, the control system controls the camera to descend and visually position the mold module on the tray, to generate the grabbing position compensation data; before the box is entered, the control system controls the camera to descend and visually position the target placement position in the box, to generate the entry position fine adjustment data.

[0034] Specifically, by integrating the gripper vision unit 4-6 on the material taking mechanism 4 and its application, the unit includes an industrial camera, a light source providing stable lighting for the camera, and a lifting drive module driving the camera to move vertically, where the lifting drive module can be selected as a precision lead screw sliding table driven by a servo motor or a linear sliding table driven by a pneumatic cylinder, the camera and the light source are fixed on the moving plate of the sliding table, the overall assembly of the gripper vision unit 4-6 is fixed on the body of the material taking mechanism 4 through the mounting bracket, and the control circuit is laid along with the gripper drag chain and connected with the control system. In the actual operation process, the unit performs two key visual positioning tasks. When the carrying truss 5 drives the material taking mechanism 4 to move to the grabbing station above the component delivery mechanism 1, the control system first controls the lifting drive module to act, drives the camera to descend to the preset imaging height close to the module, then the light source is turned on, the camera takes a photo of the target module on the tray, identifies the specific feature points on the module through image processing, compares with the theoretical coordinates, calculates the accurate position and angle deviation of the module on the tray, generates the grabbing position compensation data to correct the final grabbing pose, and after completing the grabbing and moving to the battery pack box target in-box station above, before the in-box action starts, the control system controls the camera to descend again, takes a photo of the positioning mark of the station in the box, generates the in-box position fine-tuning data, which is used to finally review and fine-tune the global compensation data obtained by the collaborative robot unit 8. Moreover, the collaborative robot unit 8 is independently arranged in the side space of the carrying truss 5, which is usually a six-axis collaborative robot. To perform high-precision positioning and state review tasks, its execution end integrates a double-vision system. The system includes: a first group of large field of view cameras: with a larger field of view angle, used for fast, large-scale global scanning and positioning of the battery pack box entering the station, obtaining the position and attitude of the box as a whole, providing an initial reference for subsequent precise operation; a second group of high-resolution small field of view cameras: with higher pixel resolution and magnification, its core function is to perform close-range, fine image acquisition on the surface of the glued area of the lower box after gluing is completed and before the module is in-boxed. The camera can effectively identify whether there are mosquitoes, fibers or other small foreign matters attached to the glued surface, the control system is in communication connection with the double-vision system, and is configured to: first control the first group of large field of view cameras to complete the global positioning of the box; then, guide the second group of small field of view cameras to perform special shooting and image analysis on the glued area. If foreign matters are detected, the system can trigger an alarm and pause the in-box process, prompting manual cleaning, so as to eliminate the risk of pollutants being encapsulated into the battery pack from the source, greatly improving the cleanliness and long-term reliability of the product.

[0035] As a preferred embodiment of the above-mentioned embodiment, as Figures 1-5As shown, the vacuum chuck assembly is installed on the movable end of the Z2-axis electric cylinder 4-2 through a zero-point quick-change disc 4-7 integrated with multiple vacuum channels; the zero-point quick-change disc 4-7 is connected with an independent vacuum control system, which includes at least three independent vacuum circuits, each of which is provided with an independent vacuum generator, a vacuum switch valve and a vacuum degree sensor; the control system monitors the vacuum degree of each vacuum circuit respectively, and alarms or executes a safety process when the vacuum degree of any circuit is lower than the set threshold.

[0036] Specifically, the vacuum chuck assembly is installed on the mounting plate of the movable end of the Z2-axis electric cylinder 4-2 through a zero-point quick-change disc integrated with multiple vacuum channels, which includes a base disc fixed with the electric cylinder end and a change disc fixed with the chuck assembly, both of which are quickly connected and separated through a pneumatic locking mechanism, and the gas path is automatically aligned and conducted when connected. The multiple vacuum channels integrated in the zero-point quick-change disc 4-7 are connected with an external vacuum control system through quick-change connectors, and the vacuum control system includes at least three completely independent vacuum circuits, each of which has an independent vacuum generator as a negative pressure source, a controlled vacuum switch valve for on-off of the circuit, and a vacuum degree sensor for real-time monitoring of the pressure value in the circuit. The control of all vacuum generators, switch valves and sensors and signal lines are connected to the system master control. The control system continuously reads the values of each vacuum degree sensor during the grabbing and carrying process, and compares them with the preset safety threshold. When the vacuum degree of any circuit fails to reach the establishment threshold in the adsorption stage or falls below the maintenance threshold in the holding stage, the control system determines that the adsorption point is invalid, and triggers a predefined safety process, which can include issuing an audible and visual alarm, displaying the specific failed circuit on the interactive interface, stopping the current movement and controlling the material taking mechanism 4 to move the module to the safety area before releasing, or trying to re-execute the grabbing according to the strategy.

[0037] As a preferred embodiment of the above embodiment, as shown in Figures 1-5 As shown, the cross beam of the carrying truss 5 uses a single heavy-load linear guide rail as the bearing and guiding mechanism, and the Y-axis slide block is straddled on the single heavy-load linear guide rail through a sliding block; the cross beam, the Y-axis slide block and its driving mechanism are configured as a sunken mounting structure, and the running plane of the Y-axis slide block is lower than the top surface of the cross beam.

[0038] Specifically, the beam body of the carrying truss 5 adopts a single heavy-load linear guide rail with high rigidity and high load capacity as the core load-bearing and guiding mechanism. The guide rail is firmly installed on the beam base through bolts, the Y-axis slide seat directly sits on the only guide rail through multiple sliders installed on the bottom of the Y-axis slide seat, and accurately slides along the length direction of the guide rail. The driving mechanism generally includes a servo motor, a speed reducer, and a gear rack or synchronous belt transmission system, which is used to drive the Y-axis slide seat to move. The entire beam, Y-axis slide seat, and its driving mechanism are designed as a sunken installation structure. Specifically, the mounting reference surface of the beam is lowered, so that the mounting height of the heavy-load linear guide rail fixed thereon is lower than the conventional high installation mode, thereby causing the track plane of the Y-axis slide seat and the material taking mechanism 4 carried thereby in space to be lower than the highest point of the top surface of the beam structure itself. The single heavy-load linear guide rail replaces the traditional double-parallel guide rail design, which reduces the mechanical structure width and overall weight of the beam, saves material costs, and releases the lateral space of the equipment, facilitating compact layout in the production line. By selecting a higher-specification heavy-load guide rail and optimizing the slider span layout, the system rigidity, running stability, and long-term precision retention of the single guide rail scheme are ensured. The sunken installation structure directly reduces the overall equipment height and gravity center of the carrying truss 5 by lowering the mounting height of the beam, which is beneficial to the installation and maintenance of the equipment in a factory building with limited height, reduces the difficulty of crane lifting and other access operations. On the other hand, the lower running height makes the stroke of the material taking mechanism 4 closer to the work surface, reducing the invalid stroke of the Z-axis lifting mechanism, which is beneficial to shorten the cycle time, and the low gravity center structure also enhances the dynamic stability of the equipment in high-speed operation.

[0039] As a preferred embodiment of the above-mentioned embodiment, as shown in Figures 1-5 The control system is configured to perform the following boxing actions: controlling the material taking mechanism 4 to carry the mold to above the target position of the box, controlling the Z1-axis electric cylinder 4-1 to lower so that the bottom of the mold enters the opening of the box; controlling the servo drive units of the end clamp mechanism 4-3 and the side clamp mechanism 4-4 to act, so that the clamping jaws are loosened by a set distance; controlling the positioning pin cylinder and the brake cylinder provided on the material taking mechanism 4 to release, so that the material taking mechanism 4 is in a floating state in the horizontal plane; and controlling the Z2-axis electric cylinder 4-2 to drive the vacuum chuck assembly and the adsorbed mold to complete the final fine descent into the box action.

[0040] Specifically, the present detailed description details the special soft boxing control logic executed by the control system, which sequentially includes the following stages: after the taking mechanism 4 carrying the battery module moves to the above of the battery pack box target position through the carrying gantry 5, the control system first controls the Z1 axis electric cylinder 4-1 to perform a downward movement, so that the bottom of the module smoothly enters the opening of the box, completing the preliminary coarse positioning, then the control system instructs the servo drive unit connected with the end clamp mechanism 4-3 and the side clamp mechanism 4-4 to act, driving the two side clamps to move a pre-set small distance in the loosening direction, which is usually a few millimeters, the purpose is to form a movable physical gap between the clamps and the module, then the control system controls the positioning pin cylinder and the brake cylinder installed on the body of the taking mechanism 4 to release at the same time, releasing the mechanical constraint on the freedom of movement of the gripper in the horizontal plane, so that the whole taking mechanism 4 is in a floating state which can be passively compliant to external force in the XY plane, after the above preparation is completed, the control system finally drives the Z2 axis electric cylinder 4-2 to act, only the vacuum chuck assembly at the end of the electric cylinder and the module held by the vacuum adsorption complete a short stroke and low speed fine descent movement in the vertical direction, until the module is accurately placed in the final assembly position in the box, and then the vacuum releases the module to be completely handed over. Effectively solves the risk of boxing jam and module surface scratching caused by box machining tolerance, thermal deformation or cumulative assembly error, secondly, the short stroke and high control precision of the Z2 axis electric cylinder 4-2 is used to independently execute the last key putting action, while the gripper body is in a floating state, so that the module can automatically fine tune the attitude in the last stage relying on gravity and contact force, conforming to the guide structure inside the box, realizing self-adaptive compensation for small position deviation, thereby achieving higher final assembly precision under heavy load conditions, furthermore, the control logic realizes accurate action planning in stages, reduces the absolute dependence on ultra-high global positioning accuracy, reduces the harsh requirements for mechanical processing and system calibration, improves the engineering feasibility and long-term operation stability of the whole system, A module automatic boxing method for CTP-S battery pack, the method comprising the following steps: S1. Module feeding and identification: control the line body integrated unit 2 to transport the component carrying mechanism 1 carrying the battery module to the grabbing station and perform lifting positioning; control the code scanning mechanism 3 to visually scan the battery module on the component carrying mechanism 1 to identify the module code, positive and negative poles and outer dimensions; S2. Box body feeding and positioning: control the PACK lifting positioning unit 6 to lift and position the carrying trolley 7 carrying the battery pack box; S3. Box visual positioning compensation: control the collaborative robot unit 8 to move its end-of-arm vision camera to take pictures of the marker points of a plurality of preset boxing stations in the battery pack box, calculate the position and angle deviation of each station, and generate position compensation data; S4. Module grabbing: control the handling gantry 5 to drive the material taking mechanism 4 to move above the grabbing station; control the handling gantry 5 to drive the material taking gripper 4 to move above the grabbing station; control the Z1-axis electric cylinder 4-1 to lower to a preset height; first control the vacuum suction disc assembly to adsorb the module; then control the Z1-axis electric cylinder 4-1 to lift the module to make it separate from the tray; then control the end clamp mechanism 4-3 and the side clamp mechanism 4-4 to close under servo drive to clamp the module, and the pressure sensor feeds back the clamping force in real time; S5. Module boxing: according to the position compensation data, control the handling gantry 5 to drive the material taking mechanism 4 to carry the module to move above the target boxing station; control the Z1-axis electric cylinder 4-1 to lower to make the bottom of the module enter the box opening; control the end clamp mechanism 4-3 and the side clamp mechanism 4-4 to loosen the clamping jaw by a preset distance; control the positioning pin air cylinder and brake air cylinder on the material taking mechanism 4 to release; control the Z2-axis electric cylinder 4-2 to independently drive the vacuum suction disc assembly at its end to drive the module adsorbed by the vacuum suction disc assembly to complete fine lowering, and after placing the module at a predetermined position in the box, release the vacuum; S6. Cycle and circulation: control the material taking mechanism 4 to reset, the handling trolley 7 circulates to the next station, and steps S1 to S5 are repeated until the boxing of all modules is completed.

[0041] Specifically, through the automatic operation process based on the foregoing system, the method sequentially performs the following steps: first, a module loading and identification step S1 is performed, the control system schedules the line body integrated unit 2 to receive the component conveying mechanism 1 loaded with the battery module from the upstream process and accurately convey it to the preset grabbing station, after being in place, drive the built-in jacking mechanism to lift the tray and lock it in the predetermined position, ensure that all modules are at a uniform known height and plane coordinates, and at the same time, the control system triggers the code scanning mechanism 3 installed on the truss, a plurality of vision cameras thereof synchronously shoot each module on the tray, identify and record the two-dimensional code information on the surface of the module through image processing algorithms, visually judge the positive and negative directions of the cell pole, and measure the contour size of the module, complete the confirmation of the module identity and the collection of the initial data, secondly, a box loading and positioning step S2 is performed, the conveying device transports the carrying trolley 7 carrying the lower box of the battery pack to the box loading station, the control system immediately starts the PACK jacking positioning unit 6, the jacking mechanism of which lifts the carrying trolley 7 as a whole, eliminates the positioning error caused by factors such as tire suspension, and fastens the box in the predetermined zero position through lateral clamping or positioning pin devices, establishes a reference for subsequent accurate assembly, the third step is to perform a box visual positioning compensation step S3, the control system drives the collaborative robot unit 8 to move, so that the high-precision vision camera mounted at the end thereof moves above each preset module mounting station in the battery pack box in turn, takes pictures of the two or more optical markers preset, calculates the deviation of each marker point in X, Y, Z and rotation angle between the actual position and the theoretically designed position through the visual processing software, and finally generates a global position compensation data list corresponding to all stations, the first group of large field of view cameras of the collaborative robot unit 8: have a larger field of view angle, are used for fast, large-range global scanning and positioning of the battery pack box entering the station, and obtain the position and attitude of the box as a whole, providing an initial reference for subsequent precise operation; the second group of high-resolution small field of view cameras perform close-range and fine image acquisition on the surface of the glue coating area after glue coating and before module loading into the box. The camera can effectively identify whether there are mosquitoes, fibers or other small foreign matters on the glue coating surface, the control system is in communication connection with the double vision system and is configured to: first, control the first group of large field of view cameras to complete the global positioning of the box; then, guide the second group of small field of view cameras to perform special shooting and image analysis on the glue coating area. If foreign matters are detected, the system can trigger an alarm and pause the box loading process, prompting manual cleaning, thereby eliminating the risk of pollutants being encapsulated into the battery pack from the source, greatly improving the cleanliness and long-term reliability of the product, the fourth step is to perform a module grabbing step S4, the grabbing hand 4 first moves above the positioned component conveying mechanism 1, and the Z1 axis cylinder 4-1 descends to a preset height. Subsequently, the control system first controls the vacuum suction cup assembly to stably adsorb the module. Then, the Z1 axis cylinder 4-1 is controlled to rise, stably lifting the module from the tray to leave a safe clamping space for it.After the mold module is completely separated from the tray, the end clamping mechanism 4-3 and the side clamping mechanism 4-4 are controlled to move towards each other under the drive of the servo drive units thereof, and the mold module is stably closed and clamped. During the process, the force value is fed back in real time by the pressure sensor for closed-loop control. In the fifth step, the mold module enters the box S5. The control system calls the position compensation data corresponding to the current target station generated in step S3, controls the carrying gantry 5 to drive the taking mechanism 4 to carry the mold module to move above the station and perform preliminary correction, then controls the Z1 axis electric cylinder 4-1 to descend so that the bottom of the mold module enters the opening of the box, and then controls the servo drive units of the end clamping mechanism 4-3 and the side clamping mechanism 4-4 to move the clamping jaws reversely by a preset small distance, so that a movable gap is formed between the clamping jaws and the mold module. At the same time, the positioning pin cylinder and the brake cylinder on the taking mechanism 4 body are released to release the rigid constraint of the gripper in the horizontal plane and make it in a floating state. Finally, the control system only drives the Z2 axis electric cylinder 4-2 to perform a low-speed and precise descending movement, and the mold module is placed in the final assembly position by relying on the floating state of the gripper to adapt to the inside of the box. After reaching the position, the vacuum system is controlled to break the vacuum to release the mold module. In the sixth step, the cycle and circulation step S6 is performed. After one-time entry into the box is completed, the control system controls the axes of the taking mechanism 4 to reset, and the positioning pin and the brake cylinder are locked again to prepare for the next grabbing. The system repeatedly performs steps S1 to S5 until the automatic entry into the box and assembly of all mold modules in the battery pack are completed. The method first constructs a complete intelligent closed loop of "information pre-collection, global positioning and collaborative execution". The global compensation data is generated by performing a one-time visual pre-scanning on all stations of the box before entry, so that the placement action of each mold module is based on accurate and previously known deviation correction, avoiding the time waste caused by traditional positioning one by one, greatly improving the production rhythm, and meeting the high rhythm requirement of 150 seconds. Secondly, the method deeply integrates force control and visual feedback. In the grabbing stage, the pressure sensor is used to realize closed-loop control of the clamping force to prevent damage to the battery cell. In the entry into the box stage, the unique "loose clamping jaw, release floating, precise descending" action sequence is used to convert the rigid conflict risk in heavy and precise assembly into a soft adaptive process, reducing the risk of jamming or scratching of 120-kilogram-level mold modules in the narrow box, and improving the assembly success rate and product yield. Thirdly, the method realizes the binding and tracing of quality information in the whole process. From the identification of the mold module online to the state reservation before the box entry, all key data are recorded by the system and associated with the product serial number, providing a complete data chain for the digital management and quality analysis of the production process. Finally, the method fixes the complex multi-device collaborative operation through standardized program steps, reduces the dependence on the experience of operators, ensures the consistency and stability of the production process between different batches and different products, and provides reliable support for large-scale automated production.

[0042] The above shows and describes the basic principles, main features and advantages of the present application. Those skilled in the art should understand that the present application is not limited to the above-mentioned embodiments, and the above-mentioned embodiments and descriptions in the specification are only to illustrate the principles of the present application. Without departing from the spirit and scope of the present application, various changes and improvements can be made to the present application, and these changes and improvements all fall within the scope of the claimed present application. The scope of protection of the present application is defined by the appended claims and their equivalents.

Claims

1. An automatic module loading system for CTP-S battery packs, characterized in that: It includes a line integration unit (2), a barcode scanning mechanism (3), a material picking mechanism (4), a handling gantry (5), a PACK lifting and positioning unit (6), a collaborative robot unit (8), and a control system; The line integration unit (2) is used to receive and transport the component transport mechanism (1) carrying the battery module. The scanning mechanism (3) is located above or to the side of the line integration unit (2) and is used to identify and detect the shape of the battery module on the component transport mechanism (1). The transport truss (5) is provided with a crossbeam extending along the X-axis and a drive mechanism, and a slide that moves along the Y-axis is installed on the crossbeam. The material handling gripper (4) is mounted on the slide and includes a Z1 axis electric cylinder (4-1) connected to the slide, a connecting frame mounted on the movable end of the Z1 axis electric cylinder (4-1), a Z2 axis electric cylinder (4-2) mounted on the connecting frame, and an end clamping mechanism (4-3) and a side clamping mechanism (4-4). Pressure sensors are installed on both the end clamping mechanism (4-3) and the side clamping mechanism (4-4), and a vacuum suction cup assembly is provided on the movable end of the Z2 axis electric cylinder (4-2); The collaborative robot unit (8) is located on the side of the transport gantry (5), and its execution end is equipped with dual vision cameras; The PACK lifting and positioning unit (6) is used to position the transport trolley (7) that carries the battery pack box. The control system is communicatively connected to the transport gantry (5), the material handling mechanism (4), the collaborative robot unit (8), the line integration unit (2), the barcode scanning mechanism (3), and the PACK lifting and positioning unit (6); The control system acquires position compensation data generated by the visual camera of the collaborative robot unit (8) after visually locating multiple preset positions inside the battery pack box; the control system controls the transport gantry (5) and the material picking mechanism (4) to work together according to the position compensation data, and performs gripping and placement operations through the material picking mechanism (4) to realize the gripping of the module from the line integration unit (2) and its placement into the battery pack box on the transport trolley (7).

2. The automatic module boxing system according to claim 1, characterized in that, Both the end clamping mechanism (4-3) and the side clamping mechanism (4-4) are connected to a servo drive unit; The servo drive unit includes a servo motor, a ball screw driven by the servo motor, and a magnetic scale for detecting the actual displacement of the screw nut seat or gripper. The signals from the pressure sensor and the magnetic scale are fed back to the control system. The control system performs PID calculations based on the difference between the target clamping force and the feedback signal from the pressure sensor, and outputs control quantities to the servo motor to form a closed-loop control of the clamping force. At the same time, based on the difference between the target clamping displacement and the feedback signal from the magnetic scale, the movement of the servo motor is protected against overtravel.

3. The automatic module boxing system according to claim 2, characterized in that, The servo drive unit of the end clamping mechanism (4-3) drives its gripper to move along the length direction of the module, with an effective stroke of not less than 400mm on one side to be compatible with modules with a length in the range of 150mm to 1200mm. The servo drive unit of the side clamping mechanism (4-4) drives its gripper to move along the width direction of the module, with an effective stroke of not less than 220mm on one side to be compatible with modules with a width in the range of 150mm to 700mm.

4. The automatic module boxing system according to claim 2, characterized in that, The material handling mechanism (4) also includes a quick-change docking mechanism (4-5) for connecting and quickly changing grippers of different specifications. The quick-change docking mechanism (4-5) includes a connection base installed on the output side of the servo drive unit, and a mounting base. The mating portion on the gripper side, and the pneumatic pin assembly for locking the mating portion onto the connecting base; The connecting base is equipped with a positioning pin and a positioning sensor to detect whether the docking part is in place. Both the pneumatic pin assembly and the positioning sensor are communicatively connected to the control system.

5. The automatic module boxing system according to claim 4, characterized in that, The end clamping mechanism (4-3) integrates a first pressure sensor on its jaws for detecting the contact pressure on the end face of the module; the side clamping mechanism (4-4) integrates a second pressure sensor on its jaws for detecting the contact pressure on the side face of the module; during the clamping process, when the pressure value detected by the first pressure sensor reaches a first preset threshold, the first preset threshold ranges from 0N to 20000N, and / or the pressure value detected by the second pressure sensor reaches a second preset threshold, the control system controls the corresponding servo drive unit to stop feeding and maintain the position.

6. The automatic module boxing system according to claim 1, characterized in that, It also includes a gripper vision unit (4-6) mounted on the material handling mechanism (4); the gripper vision unit (4-6) includes a camera, a light source that provides illumination for the camera, and a lifting drive module that drives the camera to move in the vertical direction; the lifting drive module is a servo motor-driven screw slide or a cylinder-driven linear slide; after the material handling mechanism (4) is positioned above the gripping station, the control system controls the camera to descend and performs visual positioning of the module on the tray, generating gripping position compensation data; before entering the box, the control system controls the camera to descend and performs visual positioning of the target placement position inside the box, generating box entry position fine-tuning data.

7. The automatic module boxing system according to claim 1, characterized in that, The vacuum suction cup assembly is mounted on the movable end of the Z2 axis electric cylinder (4-2) via a zero-point quick-change plate (4-7) integrating multiple vacuum paths; the zero-point quick-change plate (4-7) is connected to an independent vacuum control system, which includes at least 3 independent vacuum circuits, each of which is equipped with an independent vacuum generator, vacuum switch valve and vacuum degree sensor; the control system monitors the vacuum degree of each vacuum circuit, and alarms or executes a safety procedure when the vacuum degree of any circuit is lower than a set threshold.

8. The automatic module boxing system according to claim 1, characterized in that, The crossbeam of the transport truss (5) uses a single heavy-duty linear guide as the load-bearing and guiding mechanism. The Y-axis slide sits on the single heavy-duty linear guide via a slider. The crossbeam, the Y-axis slide and its driving mechanism are configured as a sinking installation structure. The running plane of the Y-axis slide is lower than the top surface of the crossbeam.

9. The automatic module boxing system according to any one of claims 1 to 8, characterized in that, The control system is configured to perform the following box-entry actions: control the material handling mechanism (4) to move the module to above the target position of the box, control the Z1 axis electric cylinder (4-1) to descend so that the bottom of the module enters the box opening; control the servo drive units of the end clamping mechanism (4-3) and the side clamping mechanism (4-4) to move so that the clamps are released by a set distance; control the positioning pin cylinder and the brake cylinder on the material handling mechanism (4) to release so that the material handling mechanism (4) is in a floating state in the horizontal plane; control the Z2 axis electric cylinder (4-2) to drive the vacuum suction cup assembly and the adsorbed module to complete the final fine descent box-entry action.

10. A method for automatically loading modules into a box for CTP-S battery packs, characterized in that, The method, applied to the automatic module boxing system according to any one of claims 1 to 9, comprises the following steps: S1. Module loading and identification: Control the line integration unit (2) to transport the component transport mechanism (1) carrying the battery module to the gripping station and perform lifting and positioning; control the barcode scanning mechanism (3) to perform visual scanning on the battery module on the component transport mechanism (1) to identify the module code, positive and negative terminals and external dimensions; S2. Loading and positioning of the battery pack: Control the PACK lifting and positioning unit (6) to lift and position the transport trolley (7) carrying the battery pack; S3. Box visual positioning compensation: Control the collaborative robot unit (8) to move the visual camera at its end, take pictures of the marked points of multiple preset box entry stations in the battery pack box, calculate the position and angle deviation of each station, and generate position compensation data; S4. Module gripping: Control the transport gantry (5) to drive the material gripper (4) to move above the gripping station; control the Z1 axis electric cylinder (4-1) to descend to a preset height; first control the vacuum suction cup assembly to adsorb the module; then control the Z1 axis electric cylinder (4-1) to lift the module to remove it from the tray; then control the end clamping mechanism (4-3) and the side clamping mechanism (4-4) to close under servo drive to clamp the module, and the pressure sensor provides real-time feedback of the clamping force; S5. Module insertion: Based on the position compensation data, control the transport gantry (5) to drive the material handling mechanism (4) to move the module above the target insertion station; control the Z1 axis electric cylinder (4-1) to descend so that the bottom of the module enters the box opening; control the end clamping mechanism (4-3) and the side clamping mechanism (4-4) to release the clamps by a preset distance; control the positioning pin cylinder and brake cylinder on the material handling mechanism (4) to release; control the Z2 axis electric cylinder (4-2) to independently drive the vacuum suction cup assembly at its end, so that the module adsorbed by the vacuum suction cup assembly completes a fine descent, and after placing the module in the predetermined position in the box, release the vacuum; S6. Cycle and Flow: Control the material picking mechanism (4) to reset, and the transport trolley (7) to flow to the next station. Repeat steps S1 to S5 until all modules are put into the box.

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