Automatic bending and leveling device and method for soft package module tabs

Abstract

The invention relates to the technical field of soft package power batteries, and discloses a soft package module tab automatic bending and leveling device and method.The soft package module tab automatic bending and leveling device comprises a main body support serving as a device bearing framework; the bending assembly comprises a shifting piece, a servo driving unit and a first visual detection unit, the shifting piece is in transmission connection with the servo driving unit, and the signal output end of the first visual detection unit is in communication connection with the control end of the servo driving unit; the leveling assembly comprises a transverse rolling wheel and a longitudinal rolling wheel which are sequentially arranged in the flowing direction of the tabs, and the transverse rolling wheel and the longitudinal rolling wheel are each provided with an elastic pressing unit; and the second visual detection unit is arranged at the downstream station of the longitudinal roller, and the detection area of the second visual detection unit corresponds to the lap joint area of the tab. The defect that the bending effect is influenced due to product difference is compensated according to visual compensation, the tab is prevented from being pressed and deformed in the stretching and retracting process of the shifting piece, the tab is leveled in the transverse direction and the longitudinal direction, the tab is prevented from rebounding after being bent, and therefore it is guaranteed that the tab can achieve the smoother effect.

Description

Technical Field

[0001] This invention relates to the field of soft-pack power battery technology, specifically to an automatic bending and leveling device and method for the tabs of a soft-pack module. Background Technology

[0002] The tabs of pouch batteries play a crucial role in connecting the battery's internal circuitry to the external circuitry. To reduce internal resistance and optimize internal space layout, the tabs are typically designed to be extremely thin, with a thickness of only 0.2 to 0.3 millimeters. While this thin design increases the battery's energy density, it also results in weak mechanical strength and insufficient rigidity of the tabs themselves. In the manufacturing process of pouch batteries, bending and flattening the tabs before connection is a critical step. Due to their extremely thin nature, they are highly susceptible to plastic deformation, positional displacement, and stress rebound during processing, leading to significant uncertainties in their condition.

[0003] Therefore, this process currently relies primarily on the operator's experience and feel for manual bending and flattening. Because the tab material is soft and easily deformed, its bent state depends not only on the applied force but also on the material's springback characteristics, the cell's flatness, and the packaging condition. Subtle differences in each cell, such as the initial tab position, wrinkles or slight bulges caused by the aluminum-plastic film packaging, can create additional irregularities, leading to errors in subsequent processing and increasing cumulative errors. Operators need to observe, judge, and adjust in real time, resulting in a heavy workload and difficulty in ensuring consistent adjustments.

[0004] This method is not only inefficient and costly, but also makes it difficult to precisely control and maintain bending angles, flatness, and bonding positions, resulting in poor consistency in the tab's condition. These process fluctuations directly affect the positioning accuracy and connection reliability of subsequent welding, thus limiting the uniformity of overall battery performance and the controllability of the production process. Summary of the Invention

[0005] The present invention aims to provide an automatic bending and leveling device and method for tabs of soft-pack modules, so as to solve the problem of inconsistent processing status of existing tabs and the difficulty in achieving automated bending and leveling.

[0006] To achieve the above objectives, the present invention employs the following technical solution: an automatic bending and leveling device for tabs of flexible modules, comprising: The main support frame serves as the structural support for the device. The bending assembly includes a lever, a servo drive unit, and a first vision detection unit. The lever is connected to the servo drive unit in a transmission manner, and the signal output terminal of the first vision detection unit is communicatively connected to the control terminal of the servo drive unit. The leveling assembly includes a transverse roller and a longitudinal roller arranged sequentially along the tab's flow direction, and both the transverse roller and the longitudinal roller are equipped with elastic clamping units. The second visual detection unit is located at the downstream end of the longitudinal roller, and its detection area corresponds to the overlapping area of ​​the tab.

[0007] Meanwhile, this solution also provides an automatic bending and leveling method for tabs of flexible packaging modules, applied to the aforementioned automatic bending and leveling device for tabs of flexible packaging modules, including the following steps: S1, the module with the tabs is sent into the leveling device. After the module is in place, the position of the tabs is detected by the first vision detection unit, and the compensation amount that the lever needs to move is calculated and sent to the servo drive unit. S2, the servo drive unit drives the paddle to move to the designated position according to the compensation amount, and extends the paddle out of the plastic bracket surface close to the battery through the transmission rod; S3, control the paddle to move in the specified direction to pre-bend the electrode tab; S4, the servo drive unit compresses the spring behind the horizontal roller to a fixed size, so that the horizontal roller flattens the tab for the first time along the bending direction; S5. Repeat S2 to S4. After all tabs are pre-bent and initially leveled, the longitudinal roller and spring are compressed to a fixed size by the servo drive unit, so that the longitudinal roller can level the tabs a second time along the Z-axis. S6. The leveling effect of the tabs is detected by the second vision detection unit. If the detection is qualified, it will proceed to the next process.

[0008] The principles and advantages of this scheme are: In existing technologies, even when mechanical bending is used, fixed molds or rigid structures are commonly employed, only suitable for single-specification tabs. This makes it difficult to compensate for differences in bending performance caused by product variations when dealing with different models, resulting in a generally high defect rate. Secondly, existing technologies mostly involve unidirectional leveling, which only alleviates surface warping but cannot eliminate internal stress in the tabs, leading to a rebound rate exceeding 15%. Finally, offline inspection by operators is still required, posing a high risk of defective products leaking out and lacking traceability, resulting in poor overall bending performance. The need for operator intervention in bending and inspection further reduces bending efficiency and increases costs.

[0009] This solution deeply integrates visual inspection and servo compensation, which can compensate for the impact of bending effects caused by product differences through visual compensation. At the same time, the elastic buffer component replaces the traditional rigid connection, which can prevent the tab from deforming during the extension and retraction of the lever.

[0010] Secondly, this solution, based on the principle of metal stress relief, creatively designs an orthogonal leveling structure. The synergistic effect of the transverse and longitudinal rollers improves the stress relief rate and provides stable downward pressure during the leveling process. This maximizes the elimination of stress after the tabs are bent, preventing rebound and ensuring a smoother surface. Simultaneously, the adjustable elastic downward pressure adapts to tabs of different thicknesses, resolving the contradiction in existing devices where "fixed pressure leads to insufficient leveling of thin tabs and excessive compression of thick tabs."

[0011] Finally, this solution integrates the inspection process at the end of the device, synchronizing the inspection cycle with the processing cycle to achieve real-time online rejection of defective products and ensure subsequent welding results. At the same time, the inspection data can be uploaded to provide data support for the optimization of servo compensation parameters, forming a continuous improvement mechanism of "inspection-feedback-adjustment" to significantly improve the overall processing pass rate. Attached Figure Description

[0012] Figure 1 This is a schematic diagram of the transverse roller structure of an automatic bending and leveling device for the tabs of a soft-pack module according to the present invention; Figure 2 for Figure 1 Enlarged view of part A in the image; Figure 3 This is a schematic diagram of the longitudinal roller structure of an automatic bending and leveling device for tabs of a soft-pack module according to the present invention; Figure 4 for Figure 3 Enlarged view of part B in the image; Figure 5 This is a flowchart illustrating an automatic bending and leveling method for tabs of a flexible module according to the present invention. Figure 6 This is a diagram showing the effect of the tab module before leveling in the automatic bending and leveling method for the tabs of a soft-pack module according to the present invention. Figure 7 This is a diagram showing the effect of leveling the tab module in the automatic bending and leveling method for the tab of a soft-pack module according to the present invention.

[0013] The markings in the accompanying drawings include: main support 1, lever 2, servo drive unit 3, first vision detection unit 4, buffer assembly 5, transmission rod 6, mounting base 7, transverse roller 8, longitudinal roller 9, elastic clamping unit 10, long U-shaped support 11, long roller shaft 12, short U-shaped support 13, short roller shaft 14, second vision detection unit 15, and plastic support surface 16. Detailed Implementation

[0014] The following detailed description illustrates the specific implementation method: This embodiment presents an automatic bending and leveling device and method for the tabs of a soft-pack battery module. It employs visual compensation and horizontal and vertical rollers to accurately and efficiently achieve the bending and leveling operation of the tabs of the soft-pack battery cells, overcoming the difficulty of achieving automated bending and leveling due to the inconsistent state of the tabs of the soft-pack battery cells.

[0015] Option 1 An automatic bending and leveling device for tabs of flexible packaging modules is provided, as shown in the attached document. Figure 1 As shown, it includes: The main support frame 1 serves as the structural framework supporting the device. In this embodiment, the main support frame 1 is a rectangular parallelepiped structure with multiple sets of mounting holes on its surface. Bending components, leveling components, and vision inspection units are fixedly mounted to their corresponding positions on the support frame using bolts. The relative tolerances of each component are controlled within ±0.5mm. This structure supports all components, ensuring the relative positional accuracy and stability of each mechanism.

[0016] The bending assembly includes a lever 2, a servo drive unit 3, and a first vision detection unit 4. The lever 2 is connected to the servo drive unit 3 by means of transmission, and the signal output terminal of the first vision detection unit 4 is communicatively connected to the control terminal of the servo drive unit 3.

[0017] In this embodiment, as shown in the appendix Figure 2 As shown, the paddle 2 has a wedge-shaped structure with a narrow front end to facilitate pre-bending of the tab from the side. A mounting base 7 is bolted to the lower end of the paddle 2; in this embodiment, the mounting base 7 has a stepped structure. A transmission rod 6 is located at the lower end of the mounting base 7, which drives the paddle to extend and retract. A servo drive unit 3 is located at the drive end of the transmission rod 6, which drives the transmission rod 6 to achieve the extension and retraction movement.

[0018] In this embodiment, the servo drive unit 3 is a linear servo module. The slider of the servo module is fixed relative to the mounting base 7. One end of the transmission rod 6 is fixed to the module slider via a thread or keyway. The movement stroke of the slider is controlled by signal feedback from the first vision detection unit. A buffer assembly 5 is provided between the paddle 2 and the servo drive unit 3. Specifically, the buffer assembly 5 is a disc spring sleeved on the outside of the transmission rod 6. In this embodiment, the linear servo module is driven by a linear servo motor.

[0019] The leveling assembly includes a transverse roller 8 and a longitudinal roller 9 arranged sequentially along the direction of the tab's rotation. In this embodiment, both the transverse roller 8 and the longitudinal roller 9 are equipped with an elastic clamping unit 10. In this embodiment, the elastic clamping unit 10 is a spring mechanism, with one end connected to the transverse roller / longitudinal roller and the other end connected to the main support 1.

[0020] As attached Figure 2As shown, in this embodiment, the transverse roller 8 includes two sets of longitudinally arranged long U-shaped support seats 11, which are arranged in the same direction as the lever 2 and are respectively located on both sides of the lever 2. Long roller shafts 12 are installed on the side ears of the long U-shaped support seats 11 for initial leveling of the pre-bent electrode ears. The lower end of the long U-shaped support seat 11 is connected to the telescopic end of the elastic pressing unit 10, used to compress the rear spring of the roller to a fixed size to ensure a fixed pressure is provided.

[0021] As attached Figure 3 and attached Figure 4 As shown, in this embodiment, the longitudinal roller 9 includes two sets of transversely arranged short U-shaped support seats 13, that is, arranged perpendicular to the direction of the long U-shaped support seat 11. Short roller shafts 14 are provided on the short U-shaped support seats 13. In this embodiment, the short U-shaped support seats 13 are shorter in length than the long U-shaped support seats 11, but their height is greater than that of the long U-shaped support seats 11. The width of the short roller shaft 14 is slightly larger than the width of the electrode lug, ensuring that it can completely cover the entire bending surface of the electrode lug. The width of the long roller shaft 14 is slightly larger than the length of the electrode lug, ensuring that it can completely cover the entire bending surface of the electrode lug from the side.

[0022] Meanwhile, the lower end of the short U-shaped support 13 is connected to the telescopic end of the elastic clamping unit 10.

[0023] The second visual inspection unit 15 is located at the downstream end of the longitudinal roller 9. The camera is fixed to the main structure by a bracket. Its inspection area corresponds to the overlap area of ​​the tabs and is used to inspect the overlap size of the tabs.

[0024] In this embodiment, both the first visual inspection unit 4 and the second visual inspection unit 15 are fixed to the main support 1 by brackets, with their lenses facing the corresponding inspection area of ​​the tab. Specifically, the first visual inspection unit 4 can be an industrial CCD camera, with the camera lens facing the tab feeding station, and the camera's image acquisition frequency matching the tab feeding speed. The second visual inspection unit 15 can also be an industrial CCD camera, with its lens aimed at the overlapping area of ​​the tab after secondary leveling. The camera communicates with the host computer, which has a built-in size comparison algorithm.

[0025] Option 2 An automatic bending and leveling method for tabs of flexible packaging modules is provided, which is applied to the aforementioned automatic bending and leveling device for tabs of flexible packaging modules, as shown in the attached figure. Figure 5 As shown, it includes the following steps: S1, the module with tabs is sent into the leveling device. After the module is in place, the position of the tabs is detected by the first vision detection unit, and the compensation amount that the lever needs to move is calculated and sent to the servo drive unit.

[0026] In this embodiment, as shown in the appendix Figure 6As shown, the tab module contains multiple sets of tabs, and each tab needs to be bent and flattened sequentially. The tabs enter the bending station along with the workpiece. The camera lens of the first vision detection unit 4 faces the tab feeding station and captures images of the tabs. First, it identifies the deviation between the actual position and the theoretical position of the first tab and transmits the deviation signal to the controller of the servo drive unit 3. The image acquisition frequency of the camera is matched with the feeding speed of the tabs.

[0027] In this embodiment, the first visual detection unit 4 includes a coordinate transformation module and a deviation calculation module. The coordinate transformation module converts the pixel coordinates of the tab into physical coordinates, and the deviation calculation module calculates the position deviation based on the theoretical coordinates and actual physical coordinates of the tab. The deviation calculation formula is as follows: ; in, , These are the actual physical coordinates of the electrode; , These are the theoretical coordinates for the electrode. The calculated deviation signal is transmitted to servo drive unit 3.

[0028] S2, the servo drive unit drives the paddle 2 to move to the designated position according to the compensation amount, and extends the paddle out of the plastic bracket surface 16 close to the battery through the transmission rod.

[0029] In this embodiment, the servo drive unit 3 controller drives the slider of the linear servo module to move, causing the lever 2 to reach the target position after the first tab compensation. Subsequently, the servo module pushes the lever 2 against the surface of the plastic bracket of the workpiece via the transmission rod 6, as shown in the attached figure. Figure 6 The plastic bracket on the outside of the electrode is positioned as shown, so that it fits close to the designated location without damaging the electrode.

[0030] S3 controls the lever to move in the specified direction to pre-bend the electrode tab.

[0031] Then, control the lever 2 to move in the specified direction to pre-bend the electrode tab. In this embodiment, for the first electrode tab, control the lever 2 to move inward to pre-bend it inward.

[0032] S4, through the servo drive unit, compresses the spring behind the transverse roller to a fixed size, so that the transverse roller flattens the tab for the first time along the bending direction.

[0033] After pre-bending is completed, the paddle 2 is removed, and the bent tab moves with the workpiece to the transverse roller 8. The servo drive unit compresses the spring behind the transverse roller to a fixed size to ensure that a fixed pressure is provided. Then, the transverse roller 8 flattens the tab for the first time along the bending direction, i.e., the inside of the tab.

[0034] S5, repeat S2 to S4. After all tabs are pre-bent and initially leveled, the servo drive unit compresses the spring behind the longitudinal roller to a fixed size, causing the longitudinal roller to level the tabs a second time along the Z-axis. The effect is shown in the attached figure. Figure 7 As shown.

[0035] In this embodiment, after pre-bending and first leveling the multiple battery tabs according to the above steps, the tabs are then moved to the longitudinal roller 9. The servo drive unit compresses the spring behind the longitudinal roller to a fixed size, ensuring consistent pressure. The longitudinal roller then levels the tabs a second time along the Z-axis. That is, the first leveling is along the width of the tab, and the second leveling is along its length. Leveling in both the X and Y axes minimizes stress after bending the tabs, preventing rebound and ensuring a smoother surface.

[0036] S6. The leveling effect of the tabs is detected by the second vision detection unit. If the detection is qualified, it will proceed to the next process.

[0037] In this embodiment, after leveling is completed, the overlapping area of ​​the electrode tab is photographed by the second vision detection unit 15, and the host computer compares the measured size with the standard size to detect the bending and leveling effect of the electrode tab, thereby ensuring the subsequent welding effect.

[0038] In existing technologies, electrode tab bending often uses fixed molds, which have a limited range of applications. When dealing with multiple models, the initial positional deviation of the electrode tabs cannot be compensated for, resulting in inconsistent bending angles and requiring operator intervention for adjustment. Furthermore, residual deformation of the electrode tabs is prone to occur after bending, affecting the accuracy of the interlocking connection. Subsequent inspection also relies on operator intervention, leading to unstable inspection results and low efficiency.

[0039] In this embodiment, different specifications of tabs can be adapted simply by adjusting visual parameters, without changing the mold. The model switching time is reduced from 40 minutes in the existing technology to 20 minutes, meeting the needs of "multi-variety, small-batch" production and improving product adaptability. Leveling is performed in both horizontal and vertical directions, and stable downward pressure is provided during the leveling process, which can eliminate stress after the tabs are bent to the greatest extent and prevent rebound after bending, thus ensuring a flatter tab. The bending angle error of the tabs is ≤±1°, and the overlap size accuracy is ±0.5mm, fully meeting the stringent requirements for tab flatness in subsequent laser welding and improving the stability of processing quality. Then, combined with visual inspection, online inspection is achieved, improving the reliability and stability of inspection, and increasing overall production efficiency and product yield.

[0040] The above descriptions are merely embodiments of the present invention, and common knowledge such as specific technical solutions and / or characteristics are not described in detail here. It should be noted that those skilled in the art can make various modifications and improvements without departing from the technical solutions of the present invention, and these should also be considered within the scope of protection of the present invention. These modifications and improvements will not affect the effectiveness of the implementation of the present invention or the practicality of the patent. The scope of protection claimed in this application should be determined by the content of its claims, and the specific embodiments described in the specification can be used to interpret the content of the claims.

Claims

1. A soft package module tab automatic bending and flattening device, characterized in that, The device comprises: a main support as a device carrying framework; a bending assembly comprising a push piece, a servo drive unit and a first visual detection unit, the push piece being in transmission connection with the servo drive unit, and the signal output end of the first visual detection unit being in communication connection with the control end of the servo drive unit; a flattening assembly comprising a transverse roller and a longitudinal roller arranged in sequence along the flow direction of the tab, and the transverse roller and the longitudinal roller are both provided with an elastic compression unit; a second visual detection unit arranged at the downstream end of the longitudinal roller, and the detection area of the second visual detection unit corresponds to the lap area of the tab.

2. The soft package module tab automatic bending and flattening device according to claim 1, characterized in that: The elastic compression unit is a spring mechanism, one end of the spring mechanism is connected with the transverse roller / longitudinal roller, and the other end is connected with the main support. 3.The soft-pack module tab automatic bending and flattening device of claim 1, wherein: A buffer assembly is arranged between the push piece and the servo drive unit, and the buffer assembly is a butterfly spring sleeved on the outside of a transmission rod.

4. The soft package module tab automatic bending and flattening device of claim 1, wherein: The first visual detection unit and the second visual detection unit are both fixed on the main support through a support, and the lens is directed towards the corresponding detection area of the tab.

5. The automatic bending and flattening device for soft package module tab according to claim 3, characterized in that: A mounting seat is arranged at the lower end of the push piece, and a transmission rod is arranged at the lower end of the mounting seat; the servo drive unit is a linear servo module, the slider of the servo module is fixed opposite to the mounting seat, and the moving stroke of the slider is controlled by the signal feedback of the first visual detection unit. 6.The soft-pack module tab automatic bending and flattening device of claim 1, wherein: The transverse roller comprises two groups of longitudinally arranged long U-shaped support seats, and a long roller shaft is arranged on the long U-shaped support seat; the lower end of the long U-shaped support seat is connected with the telescopic end of the elastic compression unit.

7. The automatic bending and flattening device for soft package module tab according to claim 6, characterized in that: The longitudinal roller comprises two groups of transversely arranged short U-shaped support seats, and a short roller shaft is arranged on the short U-shaped support seat; the lower end of the short U-shaped support seat is connected with the telescopic end of the elastic compression unit.

8. A soft package module tab automatic bending and flattening method, characterized in that, The device is applied to the soft-pack module tab automatic bending and flattening device of any one of the above claims 1-7, and comprises the following steps: S1, a module provided with a tab is sent into the flattening device, after the module is in place, the position of the tab is detected by the first visual detection unit, and the compensation amount that the push piece needs to move is calculated, and the compensation amount is sent to the servo drive unit; S2, the servo drive unit drives the push piece to move to the specified position according to the compensation amount, and the push piece is stretched out close to the plastic support surface of the battery through the transmission rod; S3, the push piece is controlled to move in the specified direction to pre-bend the tab; S4, the transverse roller rear spring is compressed and fixed in size by the servo drive unit, so that the transverse roller flattens the tab along the bending direction for the first time; S5, S2 to S4 are repeated, after all the tabs are pre-bent and preliminarily flattened, the longitudinal roller rear spring is compressed and fixed in size by the servo drive unit, so that the longitudinal roller flattens the tab along the Z-axis direction for the second time; S6, the flattening effect of the tab is detected by the second visual detection unit, and after the detection is qualified, the next process is entered.

9. The method of claim 8, wherein the method further comprises: The camera lens of the first visual detection unit is directly opposite the tab feeding station, and the image acquisition frequency of the camera matches the feeding speed of the tab.

10. The method of claim 8, wherein the method further comprises: The first visual detection unit is internally provided with a coordinate conversion module and a deviation calculation module, the coordinate conversion module is used for converting pixel coordinates of the tab into physical coordinates, and the deviation calculation module is used for calculating a position deviation based on theoretical coordinates and actual physical coordinates of the tab, and a deviation calculation formula is ； wherein, , are the actual physical coordinates of the tab; , are the theoretical coordinates of the tab.

Images