Flexible adaptive soft package lithium battery independent grabbing pressure feedback system

Abstract

The invention belongs to the technical field of lithium battery production equipment, and relates to a flexible adaptive soft package lithium battery independent grabbing pressure feedback system, which comprises a data storage module, a pressure acquisition module, a deformation detection module, a control unit and a driving adjustment module, the pressure acquisition module and the deformation acquisition module respectively acquire clamping surface pressure and battery surface micro-deformation data, the control unit processes double signals through a fusion algorithm, generates a driving adjustment instruction according to a pressure matching state and a deformation trend, sets a pressure-deformation dual early warning mechanism, and starts an emergency buffer program when the data exceeds a safety range. The system solves the problems of deformation, swelling and damage caused by improper pressure control when the soft package lithium battery is grabbed, realizes self-adaptive safe clamping, adapts to batteries of multiple specifications and individual differences, supports mixed flow production, can be directly connected with an existing automatic production line, and is suitable for soft package battery grabbing operation.

Description

Technical Field

[0001] This invention belongs to the field of lithium battery production equipment technology, specifically a flexible and adaptable soft-pack lithium battery independent gripping pressure feedback system. Background Technology

[0002] With the rapid development of new energy vehicles and the energy storage industry, pouch lithium batteries have been widely used due to their advantages such as high energy density and good safety performance. In the manufacturing process of pouch lithium batteries, the gripping operation is one of the key technological steps, directly affecting battery quality and production efficiency. Because pouch lithium batteries are encapsulated in an aluminum-plastic film, their structure is relatively flexible. During the gripping process on automated production lines, problems such as deformation, bulging, or even breakage can easily occur due to improper pressure control. Therefore, a precise pressure feedback control system is needed to ensure the safety and reliability of the gripping process.

[0003] CN213905436U discloses a pressure-variable formation system for soft-pack lithium batteries, including a formation device, a data acquisition card, a main control console, and a programmable controller. The formation device includes a support plate, a vertical mounting plate with its bottom fixed to the support plate, an electric cylinder fixed to the vertical mounting plate, multiple cell clamps arranged parallel to each other on the support plate, a spring connecting two adjacent cell clamps, and a pressure sensor. Among the multiple cell clamps, one end is adjacent to the electric cylinder, and the other end is away from the electric cylinder. A pressure sensor is fixed on the cell clamp adjacent to the electric cylinder, and the piston rod end of the electric cylinder is fixedly connected to the pressure sensor. The bottom end of the cell clamp away from the electric cylinder is fixed to the support plate, and the bottom ends of the remaining cell clamps are all supported on the support plate.

[0004] During the formation process of soft-pack lithium batteries, cells are placed on the support plate and between two adjacent cell clamping plates. A data acquisition card is connected to the cells on the formation device to collect voltage data. The output of the data acquisition card is connected to the main control console to transmit the collected voltage data to the main control console. At the same time, a pressure sensor is connected to the main control console to transmit the real-time pressure data of the electric cylinder to the main control console. The main control console is connected to the programmable controller. The main control console issues control commands to the programmable controller based on the voltage and pressure data. The programmable controller is connected to the electric cylinder to control the electric cylinder, thereby changing the clamping force on both sides of the cell.

[0005] CN118936719A discloses a device for measuring the internal pressure of a pouch battery, comprising a device body, one end of which has a planar pressure head; and a sensor configured to measure pressure distribution data on the planar pressure head, or configured to measure a first total pressure on the planar pressure head and a first contact area between the planar pressure head and the expansion protrusion of the outer shell of the pouch battery.

[0006] A data acquisition and processing module, disposed on the main body of the device and connected to the sensor, is configured to acquire and process data from the sensor to obtain the internal pressure of the pouch battery. The measuring device of this application features a simple structure, ease of use, and high testing accuracy, and is capable of measuring the internal pressure of various pouch batteries.

[0007] Current technologies for gripping pouch lithium batteries still have significant shortcomings. First, existing pressure control systems lack a dynamic linkage mechanism between pressure and the drive mechanism, resulting in insufficient adaptability and safety. Existing technologies mostly employ single pressure regulation or force-position segmented switching control, with fixed parameters such as the clamping speed and stroke buffer amplitude of the drive mechanism. This allows for only passive pressure adjustment, which can easily scratch the aluminum-plastic film due to excessive impact force at the moment of contact, and can cause battery bulging due to mismatch between pressure and drive state during continuous clamping. Second, existing systems have limited adaptability, limited to size specifications, and cannot adapt pressure-drive parameters to individual differences such as pouch battery packaging tightness and cell distribution uniformity. This results in weak generalization capabilities and makes it difficult to meet the needs of mixed-production. Finally, existing systems lack the ability to predict deformation correlation, leading to delayed and irreversible damage suppression. Existing systems rely solely on passive feedback from pressure sensors, making them insensitive to minute deformations caused by the material properties of pouch batteries. They cannot predict pressure overload risks based on deformation trends, and often by the time the pressure reaches the warning threshold, the battery has already suffered irreversible bulging or scratches, making it impossible to prevent damage at the source.

[0008] Therefore, a flexible, adaptable, independent gripping pressure feedback system for soft-pack lithium batteries is proposed to address the above problems. Summary of the Invention

[0009] The purpose of this invention is to address the shortcomings of existing technologies by providing a flexible, adaptable, independent gripping pressure feedback system for soft-pack lithium batteries, thereby solving the technical problems mentioned in the background.

[0010] To achieve the above objectives, this application proposes a flexible, adaptable, independent gripping pressure feedback system for pouch lithium batteries, comprising:

[0011] The data storage module is used to store the standard deformation threshold, safe pressure range and driving reference parameters corresponding to the soft-pack battery;

[0012] The pressure acquisition module is used to acquire pressure data of the clamping surface in real time during the gripping process of the soft-pack battery;

[0013] The deformation detection module is used to collect minute deformation data of the soft-pack battery surface in real time during the soft-pack battery grasping process;

[0014] The control unit establishes communication connections with the pressure acquisition module, deformation detection module, data storage module, and drive adjustment module, respectively. The control unit processes the received pressure data and deformation data through a preset fusion algorithm, and dynamically generates drive adjustment commands based on the matching result of the pressure data and the safe pressure range value and the changing trend of the deformation data. The drive adjustment commands are fed back by the drive adjustment module when the pressure is close to a preset proportion of the safe pressure range and when the deformation data shows an upward trend of not less than a preset amplitude.

[0015] When the pressure data exceeds the safe pressure range or the deformation data exceeds the standard deformation threshold, the control unit generates a drive adjustment command and simultaneously starts an emergency buffer program to avoid damage to the pouch battery caused by a sudden failure, thus forming a dual early warning mechanism of pressure and deformation.

[0016] The drive adjustment module is used to receive and execute the drive adjustment commands of the control unit to adjust the clamping speed, stroke buffer amplitude and clamping pressure to achieve adaptive clamping of the soft-pack battery.

[0017] Preferably, the control unit is installed in the proximal region of the drive adjustment module to shorten the signal transmission path;

[0018] The pressure acquisition module, deformation detection module and control unit adopt a dual transmission mechanism of industrial Ethernet and pulse signal. The transmission delay of the pressure data, deformation data and drive adjustment command does not exceed the preset delay threshold. The control unit adopts a PLC and embedded chip collaborative architecture to ensure the real-time performance of data processing and command output.

[0019] Preferably, the emergency buffer procedure includes:

[0020] The control unit controls the drive adjustment module to quickly reduce the clamping pressure to a preset safe initial value, which is no greater than 1 / 3 of the lower limit of the safe pressure range;

[0021] The control unit synchronously controls the clamping mechanism to move back slightly away from the soft-pack battery, and the distance of the back movement is no more than 2mm.

[0022] After the pressure data returns to the safe pressure range and the deformation data returns to the standard deformation threshold, the control unit controls the drive adjustment module to execute drive adjustment commands adapted to the current state based on the real-time collected pressure data and deformation data.

[0023] Preferably, the data storage module supports manual updating or automatic iteration of the standard deformation threshold, safety pressure range, and driving reference parameters of different models of pouch batteries. By updating these parameters, it is possible to adapt to pouch batteries of various specifications with differences in packaging tightness or cell distribution uniformity, and no modification to the mechanical structure of the system is required during the adaptation process.

[0024] Preferably, the pressure acquisition module includes distributed pressure sensors, which are evenly arranged across the entire clamping surface of the pouch battery, and the spacing between the sensor acquisition points does not exceed a preset spacing threshold, for synchronous and comprehensive acquisition of pressure data from multiple points on the clamping surface.

[0025] Preferably, the deformation detection module has a detection accuracy of not less than a preset accuracy threshold. Its detection probes are distributed in a manner corresponding to the corners and middle area of ​​the pouch battery, which is used to accurately capture the minute deformations at key locations on the surface of the pouch battery and form corresponding deformation data.

[0026] Preferably, when the control unit processes the pressure data and deformation data using a preset fusion algorithm, the fusion algorithm is constructed based on the matching degree between the pressure data and the safe pressure range and the rate of change of the deformation data. The specific calculation method is as follows:

[0027] The degree of matching between the pressure data and the safe pressure range is calculated as follows:

[0028] ;

[0029] Wherein, P represents the pressure data acquired by the pressure acquisition module. This represents the upper limit of the safe pressure range stored in the data storage module. This is the lower limit of the safe pressure range stored in the data storage module;

[0030] Based on the deformation data collected by the deformation detection module, the rate of change of the deformation data is calculated, specifically as follows:

[0031] ;

[0032] in, The deformation data acquired by the deformation detection module. The time-dependent variable represents the instantaneous time interval of the deformation data. The rate of change of deformation data over time is used to reflect the real-time development trend of surface deformation of pouch batteries;

[0033] Based on the rate of change of the deformation data, the deformation trend coefficient is calculated as follows:

[0034] ;

[0035] in, This is the deformation trend coefficient, used to quantify the impact of the deformation rate on the driving regulation. The hyperbolic tangent function is used to... The values ​​are mapped to the range of -1 to 1 to avoid excessive fluctuations in the deformation trend coefficient and ensure the stability of the drive regulation. This is a preset adjustment coefficient used to adapt to the deformation characteristics of different types of pouch batteries;

[0036] The adjustment amount of the core parameter of the drive adjustment command is calculated by the following formula:

[0037] ;

[0038] in, , These are preset weighting coefficients, satisfying k1+k2=1, used to allocate the influence weights of pressure matching degree and deformation trend coefficient in drive regulation according to the model characteristics of the soft-pack battery. The core parameter adjustment amount of the drive adjustment command is used to quantitatively control the adjustment range of the clamping speed, stroke buffer amplitude and clamping pressure of the drive adjustment module;

[0039] The above step-by-step calculations enable collaborative analysis of pressure and deformation data to generate drive adjustment commands adapted to the characteristics of pouch batteries.

[0040] Preferably, when the pressure data approaches a preset percentage threshold of the safe pressure range, the drive adjustment command controls the drive adjustment module to reduce the clamping speed to a preset percentage of the reference speed corresponding to the drive reference parameter, and simultaneously increases the stroke buffer amplitude to avoid rigid impact between the clamping surface and the soft-pack battery.

[0041] Preferably, when the deformation data shows an upward trend of not less than a preset range, the drive adjustment command controls the drive adjustment module to fine-tune the clamping pressure with a preset pressure adjustment precision, and simultaneously slows down the stroke adjustment rate, thereby suppressing irreversible bulging by reverse-directing the deformation trend.

[0042] Preferably, the pressure acquisition module, deformation detection module, control unit and drive adjustment module are integrated and installed above and to the side of the gripping component of the gripping mechanism of the automated production line. This installation position design can avoid mechanical interference with the original transmission structure of the production line, and can be directly integrated without modifying the production line, thus reducing the production line modification cost.

[0043] The beneficial effects of this invention are:

[0044] By real-time acquisition and fusion analysis of pressure and deformation dual signals, a millisecond-level linkage model is constructed to achieve closed-loop control of "deformation prediction - pressure warning - instant adaptation of driving parameters". The soft-pack battery is free from bulging and scratches, and the clamping yield is greatly improved. Compared with the passive adjustment method of the existing technology, it solves the problem of grabbing impact scratches and continuous clamping bulging from a mechanism perspective.

[0045] Compared to the limitations of existing technologies that can only adapt to size specifications, this invention can adapt pressure-drive parameters to individual differences such as the tightness of pouch battery packaging and the uniformity of cell distribution, covering mainstream pouch battery specifications and individual differences, and supporting mixed-flow production needs.

[0046] Compared to the lag of existing technologies that rely solely on passive feedback from pressure sensors, this invention predicts the risk of pressure overload by analyzing deformation trends, thus preventing irreversible bulging or scratches in the battery before the pressure reaches the warning threshold, thereby avoiding damage at the source.

[0047] It can be directly integrated into existing automated production lines without requiring modification of the mechanical structure, and no large-scale equipment modification is needed. Attached Figure Description

[0048] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0049] In the attached diagram:

[0050] Figure 1 This is a schematic diagram of the system workflow of the present invention;

[0051] Figure 2 This is a schematic diagram of the working process of the pressure-deformation dual early warning and emergency buffer in this invention. Detailed Implementation

[0052] The exemplary embodiments of this disclosure are described below with reference to the accompanying drawings, including various details of the embodiments to aid understanding, and should be considered merely exemplary. Therefore, those skilled in the art will recognize that various changes and modifications can be made to the embodiments described herein without departing from the scope and spirit of this disclosure. Similarly, for clarity and brevity, descriptions of well-known functions and structures are omitted in the following description.

[0053] Specific implementation examples are given below.

[0054] A flexible, adaptable soft-pack lithium battery independent gripping pressure feedback system comprises five core components: a data storage module, a pressure acquisition module, a deformation detection module, a control unit, and a drive adjustment module.

[0055] The data storage module uses industrial-grade memory to store standard deformation thresholds, safe pressure ranges, and driving reference parameters for different models of pouch batteries. This data storage module has a built-in "mixed-flow production parameter mapping table," which pre-stores differentiated parameters for mainstream pouch battery models (e.g., 30Ah, 50Ah, 100Ah): For batteries with looser packaging (packing gap ≥ 0.1mm), the standard deformation threshold is set to 0.08mm (0.05mm for conventional batteries), and the safe pressure range is reduced by 10% (e.g., from 10-20N to 9-18N for conventional batteries); for batteries with uneven cell distribution (cell offset ≥ 0.5mm), the clamping speed reference value in the driving reference parameters is reduced by 20%, and the stroke buffer amplitude is increased by 30%, achieving individual adaptation through parameter differentiation.

[0056] The rapid changeover process in mixed-model production is as follows: After the production line's vision sensors identify the battery model and appearance features (such as the flatness of the package edge), they send a trigger signal to the data storage module. The module then calls up the corresponding parameters within 50ms and synchronizes them to the control unit, requiring no manual intervention. The adaptation and switching efficiency is ≥10 times / minute, meeting the "continuous grasping of multiple models" requirement in mixed-model production. In addition, the data storage module also supports importing parameter files output by third-party testing equipment (such as cell distribution detectors) via USB interface, enabling customized adaptation and further expanding the adaptation range.

[0057] Comparative experiments between mixed-current adaptation and individual-difference adaptation show that, using a test group containing six different types (30-200Ah) of pouch batteries, including 20% ​​with looser packaging (gap 0.1-0.15mm) and 15% with uneven cell distribution (offset 0.5-1.0mm), after 10,000 continuous production cycles, the existing technology can only adapt to one type of fixed-size battery, covering only standard-packaged batteries (gap ≤0.05mm), and is ineffective for batteries with uneven cell distribution. Batteries with a displacement ≥0.3mm are not compatible, requiring manual adjustment for 30 minutes per cycle during mixed-current switching, resulting in a mixed-current production damage rate of 4.5%. This invention, through parameter iteration and individual adaptation design, can adapt to six different battery models, expanding the compatibility range of package gaps to 0.03-0.15mm, covering 95% of individual differences. It can stably adapt to batteries with cell distribution offsets ≤1.0mm, reducing the mixed-current switching time to only 50ms per cycle and lowering the mixed-current production damage rate to 0.08%. Compared to existing technologies, this invention expands the compatibility range by 5 times, significantly improves the coverage of individual differences, increases the fault tolerance rate by 233%, and greatly enhances switching efficiency, fully meeting the needs of mixed-current production.

[0058] This data storage module supports manual updates or automatic iterations. By updating parameters, it can adapt to various specifications of pouch batteries, even those with differences in packaging tightness or cell distribution uniformity, without requiring modifications to the system's mechanical structure. The data storage module establishes a complete basic database, providing personalized control parameters for different pouch battery models, thus solving the problem of existing technologies that can only adapt to standard sizes and have weak universality.

[0059] The pressure acquisition module includes distributed pressure sensors, which are evenly arranged across the entire clamping surface of the pouch battery. The spacing between the sensor acquisition points does not exceed a preset spacing threshold. In this embodiment, the preset spacing threshold is exemplarily set to 10mm. For small pouch batteries (thickness ≤ 5mm), it can be adjusted to 5mm, and for large energy storage batteries (size ≥ 500mm), it can be adjusted to 15mm to ensure no blind spots in pressure acquisition. The core basis for this spacing setting is to adapt to the structural characteristics and monitoring requirements of pouch batteries of different specifications: for conventionally sized pouch batteries (such as 30-200Ah power batteries), a 10mm spacing can ensure the monitoring accuracy of one acquisition point covering every 100mm² area (capturing local pressure differences of ±0.5N) while avoiding data processing and transmission overload caused by redundant acquisition points.

[0060] For small soft-pack batteries with a thickness of ≤5mm (such as 1-10Ah consumer electronic batteries), their structure is more fragile and their local pressure sensitivity is higher. The 5mm spacing can achieve high-resolution monitoring with one sampling point in every 25mm² area, accurately capturing pressure fluctuations in areas prone to stress concentration such as corners, and avoiding local overload damage.

[0061] For large energy storage batteries with a size of ≥500mm, the pressure distribution on the clamping surface is more gradual and the structure is more robust. The 15mm spacing can ensure no monitoring blind spots through full coverage (e.g., 34 collection points corresponding to a 500mm side length) and keep the amount of data within the system's real-time transmission and processing capabilities.

[0062] This spacing adaptation method follows the conventional design logic for flexible clamping scenarios: the smaller the battery size, the more sensitive it is to pressure fluctuations on the clamping surface, requiring denser placement of sampling points to capture subtle pressure changes; the larger the battery size, the more even the pressure distribution, allowing for a wider spacing between sampling points to avoid data redundancy. This "flexible adjustment according to battery specifications" arrangement ensures full coverage of the clamping surface for batteries of different sizes while balancing pressure monitoring accuracy and system operating efficiency. It represents a mature adaptation approach for distributed pressure sensor placement within the industry, fully guaranteeing the comprehensiveness and reliability of pressure acquisition during the gripping of batteries of different sizes.

[0063] For small pouch batteries with a thickness ≤5mm (such as 1-10Ah consumer electronics batteries), a custom capacitive array sensor is selected, with a sampling point specification of 2×2mm² / point. Arrays with a 5mm pitch can be customized (e.g., a 50×30mm array contains approximately 60 sampling points), with a sensitivity ≥1.8MPa. -1 With a response time of ≤0.5ms, it can accurately capture local pressure differences of ±0.3N. Its thin design (thickness ≤120μm) supports adhesive installation, and the cost of a single set can be controlled between 12,000 and 18,000 yuan.

[0064] For 30-200Ah conventional soft-pack power batteries, a standard capacitive pressure array is selected, configured with a 300×200mm array (containing approximately 600 sampling points), a sampling point spacing of 10mm, an accuracy of ±0.5N, supports high-frequency sampling of ≥2000Hz, and is compatible with the system timing synchronization triggering mechanism. The price of a single set is 20,000-28,000 yuan.

[0065] For large energy storage batteries with dimensions ≥500mm, a piezoresistive distributed sensor splicing array is adopted, with a sampling point spacing of 15mm, which can be spliced ​​into a 1000×500mm array (containing approximately 2200 sampling points). It features low industrial-grade temperature drift (operating temperature -40~85℃), making it suitable for high-temperature and high electromagnetic interference production line scenarios. The cost of a single set is approximately 30,000-40,000 yuan, and its linearity output characteristics can accurately match the pressure matching degree calculation requirements in the fusion algorithm.

[0066] The pressure acquisition module and deformation detection module adopt a "time-synchronous triggering mechanism": the control unit triggers the two modules to acquire data simultaneously through a synchronous pulse signal (pulse period 1ms). The acquisition timing error is ≤0.1ms, ensuring that the timestamps of the pressure data and deformation data are completely matched, avoiding misjudgment of the fusion algorithm due to asynchronous acquisition.

[0067] The acquisition frequency can be dynamically adjusted according to the gripping stage: during the gripping start-up stage (before the clamping mechanism contacts the battery), a low-frequency acquisition (500Hz) is used to reduce system power consumption; during the contact stage (when the clamping surface contacts the battery until the pressure reaches the lower limit of the safe range), the acquisition frequency switches to a high-frequency acquisition (2000Hz) to accurately capture the pressure impact and minute deformation at the moment of contact; during the stable gripping stage (when the pressure / deformation data is stable), the acquisition frequency drops back to a medium-frequency acquisition (1000Hz) to balance accuracy and power consumption. This dynamic frequency adjustment method enables the system to accurately acquire dual signal data throughout the entire gripping process. Compared with existing technologies that use fixed-frequency acquisition (mostly 500Hz), the deformation capture sensitivity during the contact stage is increased by 4 times, and the pressure impact feedback speed is increased by 2 times.

[0068] During the gripping of the pouch battery, this pressure acquisition module collects pressure data from multiple points on the clamping surface in real time at a sampling frequency of no less than 1000Hz, ensuring comprehensive monitoring of the pressure distribution on the clamping surface. The distributed pressure sensor layout design enables synchronous and comprehensive acquisition of pressure data from multiple points on the clamping surface, avoiding blind spots that may be caused by single-point monitoring, and providing an accurate data foundation for subsequent pressure analysis and control.

[0069] The deformation detection module achieves a detection accuracy of ±0.01mm, no less than a preset accuracy threshold. The module's detection probes are distributed across the corners and center of the pouch battery to precisely capture minute deformations at key locations on its surface. During the pouch battery handling process, the deformation detection module collects real-time data on these minute deformations, generating corresponding deformation data. This module can capture deformation in its early stages, providing crucial data support for prediction and adjustment, and solving the shortcomings of existing technologies such as no deformation prediction and damage lag. The deformation detection module uses fiber optic displacement sensors (array combination): detection accuracy ±0.008mm, response time 0.08ms, continuous acquisition frequency ≥2000Hz; it is configured with 6 probes, distributed across the 4 corners and 2 central areas of the battery, with a probe spacing of 20-30mm, eliminating blind spots; it supports dual transmission of industrial Ethernet and pulse signals, with a transmission delay ≤3ms, and is designed to withstand interference.

[0070] Deformation rate acquired by the deformation detection module The control unit establishes a "three-level predictive feedback" system to achieve progressive protection from "trend prediction, mild adjustment, and deep intervention":

[0071] Level 1 prediction ( =0.005~0.01mm / ms): The deformation shows a slow upward trend, and the driving adjustment command finely adjusts the clamping pressure (adjustment accuracy 0.03N) to maintain the clamping speed and avoid over-adjustment affecting the gripping efficiency;

[0072] Level 2 prediction ( =0.01~0.02mm / ms): The deformation rise rate increases, and the drive adjustment command reduces the clamping speed to 50% of the reference speed, while increasing the stroke buffer amplitude by 20% to suppress deformation acceleration;

[0073] Level 3 prediction ( ≥0.02mm / ms): When the deformation approaches the irreversible threshold, the drive adjustment command immediately reduces the clamping pressure by 10% and pauses the stroke adjustment for 0.5ms. Dynamic adaptation is then performed after the deformation trend slows down.

[0074] Comparative experiments verified that, for the same batch of 1000 soft-pack batteries (model 50Ah), the damage rate of the gripping using the three-level prediction of this invention was 0.08% (only 1 battery had a minor scratch), while the damage rate of the existing technology (no deformation prediction, only pressure feedback) was 3.2% (32 batteries had bulges / scratches).

[0075] Experimental verification of deformation prediction and dual early warning was conducted using a 50Ah pouch battery as the test object. Under extreme conditions (pressure surge rate of 5N / ms, sensor jitter interference), 500 sudden fault tests were performed. Results showed that existing technologies can only passively respond after the pressure exceeds the threshold, with a deformation capture feedback time ≥20ms. At this point, the battery has already developed irreversible bulging, resulting in a bulging prevention rate of 0%. Furthermore, a single threshold easily leads to a false trigger rate of 5.2%, and the battery damage rate reaches 100% in the face of sudden faults. In contrast, this invention, through a deformation trend prediction mechanism, can achieve prediction during the rising stage of the deformation trend, with a deformation capture feedback time ≤3ms, an 85% improvement in feedback speed compared to existing technologies. It can intervene before the pressure reaches the warning threshold, achieving a 100% irreversible bulging prevention rate. Simultaneously, through verification with 3 frames of data and deformation consistency judgment, the false trigger rate of this invention is only 0.1%, a 98.1% reduction compared to existing technologies. The emergency buffer program can be activated in 0.5ms during sudden fault handling, reducing the battery damage rate to 0%. Data shows that this invention, through the "deformation trend coefficient (… "It can detect damage trends in advance and intervene ≥17ms earlier than existing technologies. At this time, the battery deformation is still in the reversible stage of ≤0.03mm, which can completely avoid bulging and scratches."

[0076] The control unit establishes communication connections with the pressure acquisition module, deformation detection module, data storage module, and drive adjustment module, forming the core control center of the system. The control unit and drive adjustment module are integrated into the same mounting body or directly mounted on the drive adjustment module's housing to shorten the signal transmission path and improve feedback speed. The control unit adopts a PLC and embedded chip collaborative architecture to ensure real-time data processing and command output.

[0077] Alternative implementations of control unit architecture and communication connections:

[0078] As an alternative to the control unit architecture, a heterogeneous computing architecture of "FPGA + ARM chip" can also be adopted. The FPGA is responsible for the real-time acquisition and preprocessing of pressure data and deformation data (such as filtering and noise reduction), while the ARM chip is responsible for the fusion algorithm operation and the generation of drive adjustment instructions. The data processing latency can be controlled within 3ms, which is more suitable for high-speed grasping scenarios of high-rate soft-pack batteries (grabbing frequency ≥ 5 times / second).

[0079] Furthermore, the communication connection method can be replaced with a dual transmission mechanism of "industrial Ethernet + 5G edge computing": the pressure acquisition module and deformation detection module perform data preprocessing locally through 5G edge nodes, and then transmit it to the control unit through industrial Ethernet. This adapts to scenarios where production lines are scattered and wiring is difficult, and the transmission delay is still no more than 5ms, meeting real-time requirements. If the production line needs to frequently adjust the installation position, the control unit and the drive adjustment module can also use LoRa gateway wireless communication to ensure command security through encrypted transmission protocols. In this case, the control unit can be installed independently in the production line control cabinet without being integrated into the drive adjustment module housing.

[0080] The control unit uses a preset fusion algorithm to process the received pressure and deformation data. The data is processed using a fusion algorithm based on the matching degree between pressure data and the safe pressure range, and the rate of change of deformation data, to achieve collaborative analysis of pressure-deformation dual signals. Specifically, the matching degree between pressure data and the safe pressure range is first calculated using the following formula:

[0081] ;

[0082] in The pressure data is collected by the pressure acquisition module. This represents the upper limit of the safe pressure range for storage within the data storage module. This represents the lower limit of the safe pressure range for storage in the data storage module.

[0083] Based on the deformation data collected by the deformation detection module ( ), calculate the rate of change of the deformation data, specifically:

[0084] ;

[0085] in The deformation data is collected by the deformation detection module. The time-dependent variable represents the instantaneous time interval of the deformation data. The rate of change of deformation data over time is used to reflect the real-time development trend of surface deformation of pouch batteries.

[0086] Based on the rate of change of deformation data, the deformation trend coefficient is calculated as follows:

[0087] ;

[0088] in This is the deformation trend coefficient, used to quantify the impact of the deformation rate on the driving regulation. The hyperbolic tangent function is used to... The values ​​are mapped to the range of -1 to 1 to avoid excessive fluctuations in the deformation trend coefficient and ensure the stability of the drive regulation. This is a preset adjustment coefficient used to adapt to the deformation characteristics of different models of pouch batteries.

[0089] The adjustment amount of the core parameter of the drive adjustment command is calculated by the following formula:

[0090] ;

[0091] in , These are preset weighting coefficients, satisfying k1+k2=1, used to allocate the influence weights of pressure matching degree and deformation trend coefficient in drive regulation based on the model characteristics of the pouch battery. The specific scenario-based allocation is as follows:

[0092] 1. In the high-rate power battery (30-200Ah) scenario, due to the tendency of gas production to cause swelling, the deformation trend coefficient is emphasized, and k1=0.3 and k2=0.7 are set.

[0093] 2. In the scenario of small consumer electronics batteries (1-10Ah), due to the fragile structure, it is necessary to control the contact pressure, focusing on the pressure matching degree, and setting k1=0.6 and k2=0.4;

[0094] 3. For large-scale energy storage batteries (500-1000Ah), considering both pressure and deformation, k1=0.5 and k2=0.5 are set; the above weights can be automatically updated iteratively through the data storage module to adapt to changes in battery characteristics;

[0095] The core parameter adjustment amount of the drive adjustment command is used to quantitatively control the adjustment range of the clamping speed, stroke buffer amplitude, and clamping pressure of the drive adjustment module.

[0096] Pressure data and deformation data are obtained through the above step-by-step calculations. The collaborative analysis of the data is used to generate drive regulation commands adapted to the characteristics of pouch batteries.

[0097] Alternative computations for fusion algorithms:

[0098] Alternatively, the fusion algorithm can use "normalized weighted fusion + gradient correction" instead of the direct weighting method. The specific calculation process and symbol meanings are as follows:

[0099] Pressure matching degree normalization correction:

[0100] ;

[0101] in, Normalized stress matching degree (mapped to the 0.2-0.8 range to avoid interference from extreme values). , , Consistent with the previous definitions (respectively, real-time pressure data, upper limit of safe pressure, and lower limit of safe pressure);

[0102] Deformation trend coefficient gradient correction:

[0103] ;

[0104] in, This is the deformation trend coefficient after gradient correction. This is the initial deformation threshold of the pouch cell (i.e., the peak deformation of a new cell under standard clamping pressure, stored in the data storage module). , , Consistent with the previous definitions (adjustment coefficient, deformation rate, and hyperbolic tangent function, respectively);

[0105] Core adjustment optimization:

[0106] ;

[0107] in, The core parameter adjustment amount of the optimized drive adjustment command. The newly added adjustment rate weight (satisfying k1+k2+k3=1, with a value range of 0.1-0.3, adapting to the stability requirements of different batteries). To drive the rate of change of the regulation amount over time (reflecting the degree of fluctuation of the regulation command and avoiding battery shock caused by sudden parameter changes).

[0108] For novel pouch batteries without a clearly defined safe pressure range, the fusion algorithm can also be replaced by "neural network prediction fusion": a BP neural network is trained using a training set (pressure-deformation-driving parameter samples from different battery models), with pressure data as input. Deformation rate Direct output drive adjustment amount (Prediction accuracy can reach ±0.02N); where the sample dimension of the training set includes (0-50N) (0-0.05mm / ms) (-10~+10N), covering the range of parameters captured for mainstream pouch batteries, with stronger adaptability.

[0109] The control unit dynamically generates drive adjustment commands based on the matching status of pressure data with the safe pressure range and the changing trend of deformation data. Before generating drive adjustment commands, the control unit receives real-time pressure data from the pressure acquisition module at a frequency of ≥1000Hz and calculates the "pressure matching degree" hundreds of times per second using a preset fusion algorithm. ), synchronously match the safe pressure range corresponding to the current battery in the data storage module ( Then, by combining the changing trend of the deformation data, the matching status is determined and the corresponding instruction is generated.

[0110] When the pressure data approaches a preset threshold proportion within the safe pressure range, the drive adjustment command controls the drive adjustment module to reduce the clamping speed to a preset proportion of the reference speed corresponding to the drive reference parameters, and simultaneously increases the stroke buffer amplitude to avoid rigid impact between the clamping surface and the pouch battery. When the deformation data shows an upward trend not lower than a preset amplitude, the drive adjustment command controls the drive adjustment module to fine-tune the clamping pressure with a preset pressure adjustment precision, and simultaneously slows down the stroke adjustment rate, using the deformation trend to suppress irreversible bulging.

[0111] The "reverse suppression" here is specifically implemented as follows: when the deformation rise rate is detected to be ≥0.01mm / ms (preset amplitude), the clamping pressure is gradually reduced with a pressure adjustment accuracy of 0.05N / ms, while the stroke adjustment rate is slowed down from the reference 0.2mm / ms to 0.05mm / ms, so that the deformation rise trend gradually converges to ≤0.002mm / ms, thereby preventing the bulge from continuing to expand.

[0112] The control unit also features a dual warning mechanism for pressure and deformation. When the pressure data exceeds the safe pressure range or the deformation data exceeds the standard deformation threshold, to avoid false triggering of a single threshold warning and to adapt to individual battery differences, the dual warning mechanism simultaneously monitors and warns of both pressure and deformation.

[0113] The first level: pressure warning, based on pressure data, monitors the force applied when clamping the soft-pack battery and determines whether it exceeds the safe pressure range;

[0114] The second layer: Deformation warning, based on deformation data, monitors the degree of deformation of the battery during clamping and determines whether it exceeds the standard deformation threshold;

[0115] The correlation between these two types of data is as follows: pressure data corresponds to the magnitude of the clamping force, while deformation data is the physical state feedback generated by this force acting on the battery. The control unit collects both types of data simultaneously. When either type of data exceeds the corresponding threshold, and the optimized judgment mechanism verifies it as a real risk, an early warning action is initiated.

[0116] The implementation method of this solution is as follows: The control unit receives pressure data from the pressure acquisition module and deformation data from the deformation detection module in real time. First, it matches the safe pressure range value with the deformation reference value through a fusion algorithm. Then, it generates a drive adjustment command based on the data status. At the same time, it verifies the risk through a dual early warning mechanism of pressure and deformation (including false trigger identification and dynamic threshold adaptation) and then starts an emergency buffer program. Finally, the drive adjustment module executes the adjustment action to complete the adaptive clamping of the soft-pack battery.

[0117] An optimization judgment mechanism can be added before initiating the emergency buffer procedure:

[0118] 1. False Trigger Detection: Collect 3 frames of data continuously (frame interval 1ms). If all 3 frames exceed the threshold and the deformation rate is... Fluctuations ≤ ±0.001 mm / ms (excluding sensor jitter) are considered a real risk; if the fluctuation exceeds the range, it is considered a false trigger and the signal is ignored, and only normal drive adjustment is maintained.

[0119] 2. Dynamic threshold adaptation: The control unit records the first 100 deformation peak values ​​of the same battery model through the data storage module. If the historical peak values ​​are generally low (≤80% of the standard threshold), the current standard deformation threshold will be lowered by 15%. If the peak value fluctuates greatly (coefficient of variation ≥0.2), the "effective trigger duration" of this warning will be set to 2ms (the buffer program will only be started if the threshold is exceeded for 2ms continuously).

[0120] Furthermore, based on the aforementioned optimized judgment mechanism, to improve the accuracy and scenario adaptability of the early warning, the specific implementation of this pressure-deformation dual early warning mechanism can be defined as follows:

[0121] 1. Coordinated calibration of pressure and deformation:

[0122] When the pressure acquisition module detects that the pressure data is close to 90% of the upper limit of the safe pressure range, the control unit immediately retrieves the pre-stored pressure-deformation corresponding benchmark data of the same model battery from the data storage module (this benchmark data is obtained by fitting 100 sets of mass production test data of the same model battery); if the real-time deformation data at this time deviates from the standard deformation data under the corresponding pressure value in the benchmark data by more than ±5%, the control unit temporarily lowers the pressure warning threshold of this grabbing action by 3% (this adjustment only applies to the current single grabbing and does not affect subsequent batch operations), thus avoiding the risk of deformation data exceeding the threshold in advance.

[0123] 2. Contextualized adaptation for accidental trigger recognition:

[0124] To address scenarios where localized stress concentrations are prone to occur at the edges of pouch battery packaging, the control unit automatically adjusts the detection and judgment parameters accordingly.

[0125] The frame interval for collecting deformation data was adjusted from the usual 1ms to 0.5ms to improve the temporal resolution of deformation detection;

[0126] The threshold for judging the fluctuation of deformation rate is relaxed to ±0.002mm / ms; if the pressure data of three consecutive frames exceeds the safe pressure range, but the fluctuation of deformation rate exceeds the above-adjusted threshold, it is judged as a false trigger caused by local stress, and the drive adjustment module is only controlled to reduce the clamping speed to 70% of the reference speed, without starting the emergency buffer program.

[0127] 3. Tiered feedback of early warnings:

[0128] Based on the trigger type of the dual pressure-deformation warning, the control unit performs a graded buffered feedback operation on the drive adjustment module:

[0129] Single-type warning (only pressure data exceeds the threshold, or only deformation data exceeds the threshold): The control drive adjustment module reduces the clamping pressure to the safe pressure range at a rate of 0.1N / ms, while controlling the stroke of the clamping mechanism to retreat by 0.5mm, completing the first-level buffer adjustment;

[0130] Dual-type warning (both pressure and deformation data exceed the corresponding threshold): The control drive adjustment module reduces the clamping pressure to 50% of the safe lower limit with the fastest feedback speed. At the same time, it controls the clamping mechanism to move back 1mm and pauses the current gripping action for 200ms. After the battery clamping state stabilizes, normal clamping operation is resumed, completing the secondary buffer adjustment.

[0131] After confirming the actual risk through the above optimization and judgment, the control unit simultaneously initiates an emergency buffer program while generating drive adjustment commands to prevent damage to the pouch battery caused by sudden failures. The emergency buffer program includes three stages: First, the control unit controls the drive adjustment module to quickly reduce the clamping pressure to a preset safe initial value, which is no greater than 1 / 3 of the lower limit of the safe pressure range; second, the control unit simultaneously controls the clamping mechanism to retreat slightly away from the pouch battery, with a retreat distance of no more than 2mm; finally, when the pressure data returns to the safe pressure range and the deformation data returns to the standard deformation threshold, the control unit controls the drive adjustment module to execute drive adjustment commands adapted to the current state based on the real-time collected pressure and deformation data.

[0132] The drive adjustment module receives and executes drive adjustment commands from the control unit to adjust the clamping speed, stroke buffer amplitude, and clamping pressure, achieving adaptive clamping of the soft-pack battery. The multi-dimensional linkage of the drive adjustment module adopts a "parameter coupling adjustment mechanism" instead of the existing "single parameter independent adjustment": when the pressure data approaches 80% of the safe pressure range (preset proportional threshold), the clamping speed and stroke buffer amplitude are negatively correlated. The clamping speed decreases from 80% to 30% of the base speed, while the stroke buffer amplitude simultaneously increases from 0.5mm to 1.5mm. Through the coupling effect of speed reduction and enhanced buffering, the impact force at the moment of contact is reduced by more than 60%, preventing scratches on the aluminum-plastic film.

[0133] For extreme working conditions (such as slight oil stains on the battery surface or slight off-center load on the clamping mechanism), the drive adjustment module has added an "adaptive compensation function": when the pressure acquisition module detects uneven pressure distribution on the clamping surface (pressure difference ≥2N at multiple points), it automatically adjusts the slight posture of the clamping mechanism (adjustment angle ≤0.5°) and differentiates the clamping pressure in each area (reducing it by 5%-10% in high-pressure areas) to ensure uniform force on the battery; when the deformation data fluctuates abnormally due to slippage caused by oil stains, the stroke buffer amplitude is automatically increased to 1.2 times the normal value to avoid local pressure concentration caused by slippage.

[0134] Experimental verification, focusing on the dynamic linkage characteristics of pressure and drive mechanism, using a 50Ah soft-pack battery (0.12mm thick aluminum-plastic film) as the test object, with 1000 tests per group at an ambient temperature of 25℃, shows that the present invention exhibits significant advantages compared to existing technologies (single pressure adjustment). Existing technologies have an instantaneous clamping speed of 80% of the base speed (500mm / s) and a stroke buffer amplitude of only 0.3mm, resulting in an instantaneous impact force of 8.2N and a scratch rate of 2.8% on the aluminum-plastic film. In contrast, the present invention, through parameter coupling linkage, reduces the instantaneous clamping speed to 30% of the base speed (187.5mm / s), simultaneously increasing the stroke buffer amplitude to 1.5mm, ultimately reducing the instantaneous impact force to 2.4N and the scratch rate on the aluminum-plastic film to only 0.05%. Compared with existing technologies, the present invention reduces clamping speed by 62.5%, increases buffering amplitude by 400%, reduces impact force by 70.7%, and reduces scratch rate by 98.2%. Through the coupling effect of slowing down speed and increasing buffering, the present invention solves the defect of "rigid impact scratch" in existing technologies from a mechanistic perspective.

[0135] This module, through a precise actuator, can adjust the clamping parameters in real time according to control commands, ensuring safe and stable gripping of pouch batteries under different working conditions.

[0136] The pressure acquisition module, deformation detection module, and control unit employ a dual transmission mechanism of industrial Ethernet and pulse signals. The transmission delay of pressure data, deformation data, and drive adjustment commands does not exceed a preset delay threshold, controlled within 5ms, ensuring the system's real-time feedback capability. In this embodiment, the preset delay threshold is exemplarily set to 5ms. This value can be manually adjusted (within a range of 1-10ms) through the data storage module according to the real-time requirements of the production line, adapting to different grasping scenarios. This dual transmission mechanism improves the reliability and real-time performance of data transmission. Simultaneously, the control unit adopts a PLC and embedded chip collaborative architecture, further enhancing the real-time feedback capability of data processing and command output.

[0137] For extreme production line scenarios with high temperatures (≥60℃) and high electromagnetic interference (such as near welding stations), to avoid data distortion or feedback lag, the above-mentioned transmission mechanism and related modules can be enhanced with anti-interference design: the pressure acquisition module and deformation detection module adopt a "differential signal transmission + electromagnetic shielding layer" design, the sensor probe has a built-in high-temperature compensation chip (operating temperature -40℃~85℃), and a CRC-32 check + retransmission mechanism is added during data transmission. When the transmission error rate is ≥0.01%, automatic retransmission is performed to ensure that the pressure and deformation data are not distorted; at the same time, the control unit can be equipped with an "interference prediction model" to monitor the transmission error rate in real time. The battery surface temperature is monitored, and the safety redundancy of the drive adjustment command is adjusted in advance. When the bit error rate is ≥0.005%, the safety redundancy of the clamping pressure is automatically increased by 20% (the preset initial safety value is lowered to 1 / 4 of the lower limit of the safety pressure range), and the execution priority of the drive adjustment command is increased to the highest level to avoid feedback lag caused by interference. In addition, the clamping mechanism can also adopt a composite design of "ceramic insulation layer + elastic buffer pad". The ceramic insulation layer blocks the conduction of electromagnetic interference, and the elastic buffer pad (Shore hardness 50±5) absorbs mechanical vibration in extreme environments, avoiding false acquisition of pressure / deformation data caused by vibration, and further ensuring the accuracy of dynamic linkage.

[0138] Extreme environmental stability tests were conducted near the welding station on a new energy vehicle battery production line (electromagnetic interference intensity ≥100V / m) and inside a high-temperature aging chamber (60℃ / 85%RH). A 50Ah soft-pack battery was used as the test subject and continuously gripped 1000 times. The results showed that under high temperature and high humidity conditions, the existing technology had a data transmission error rate of 3.5% and a drive adjustment feedback delay of 12ms. In contrast, this invention, through differential signal transmission and CRC-32 verification design, achieved a data transmission error rate of only 0.008% and a drive adjustment feedback delay reduced to 4ms, representing a 99.8% reduction in error rate and a 66.7% reduction in delay. Under high electromagnetic interference conditions, the existing technology had a deformation data fluctuation amplitude of ±0.005mm and a gripping damage rate of 5.1%. This invention, using an electromagnetic shielding layer and an interference prediction model, controlled the deformation data fluctuation amplitude to ±0.001mm and the gripping damage rate to only 0.12%, representing an 80% reduction in fluctuation amplitude and a 97.6% reduction in damage rate. Experiments have shown that the anti-interference design of this invention can effectively cope with extreme industrial environments, ensure the stability of data transmission and drive linkage, and avoid the risk of damage caused by environmental interference.

[0139] The combination of the aforementioned basic transmission mechanism and extreme scenario anti-interference design not only maintains the high reliability and real-time performance of the dual transmission mechanism (delay ≤5ms in normal scenarios), but also maintains the stability of data transmission and command feedback in extreme environments through enhanced control architecture and anti-interference design, providing technical support for millisecond-level linkage control.

[0140] The pressure acquisition module, deformation detection module, control unit, and drive adjustment module are integrated and installed above and to the side of the gripping components of the automated production line's gripping mechanism. This installation location design avoids mechanical interference with the existing transmission structure of the production line, allowing for direct integration without modifying the production line, thus reducing production line modification costs. For different types of automated production lines, this system provides differentiated integration and adaptation solutions:

[0141] Retrofitting a traditional cylindrical battery production line: The original production line uses a pneumatic gripping mechanism. This system only requires the pressure acquisition module and deformation detection module to be glued to the inside of the gripping claw (no drilling or welding required). The control unit interfaces with the production line PLC through an adapter module, and the drive adjustment module replaces the original pneumatic control valve group. The retrofit cycle is ≤4 hours, and the cost of retrofitting a single production line is ≤50,000 yuan. Compared with building a new dedicated production line for pouch batteries (cost ≥500,000 yuan), this significantly reduces investment.

[0142] Flexible production line (multi-model switching): The system integrates "production line parameter self-learning function". During the initial installation, it automatically records parameters such as the feedback delay of the production line transmission mechanism and the mechanical clearance of the clamping mechanism through 30 trial grabs, and generates drive reference parameter correction values ​​adapted to the production line. When switching battery models later, there is no need to readjust, and the integration flexibility is significantly improved.

[0143] High-speed production line (gripping frequency ≥ 6 times / second): Adopting a "modular integrated design", the pressure acquisition module and deformation detection module are integrated into the same sensor array (thickness ≤ 3mm). The control unit and drive adjustment module adopt an integrated housing (volume reduction of 30%), reducing the installation space occupation. At the same time, the signal transmission path is optimized, so that the total delay is ≤ 2ms, which meets the real-time requirements of high-speed gripping.

[0144] Based on the customized integration solutions for different production lines described above, this system can be stably implemented and applied in various types of pouch battery production lines. Specific implementation scenarios are as follows:

[0145] New energy vehicle power battery production line scenario: Adapted to 30-200Ah high-rate soft-pack power batteries (thickness 10-20mm, aluminum-plastic film thickness 0.15mm), production line gripping frequency 5 times / second, requiring gripping damage rate ≤0.1% and supporting mixed production of more than 3 models. This system adopts an "FPGA+ARM heterogeneous control architecture", increasing the pressure acquisition frequency to 2000Hz, maintaining deformation detection accuracy at ±0.01mm, and through a three-level predictive feedback mechanism (deep intervention is initiated when the deformation change rate ≥0.02mm / ms), it specifically addresses the pain point of gas generation and easy bulging of high-rate batteries; the data storage module pre-stores differentiated parameters for 3 battery models, with the standard deformation threshold for the loosely packaged 200Ah battery set at 0.08mm and the safe pressure range adjusted to 9-18N. Parameter automatic switching is triggered by a vision sensor, with a switching efficiency of 12 times / minute, fully meeting the requirements of mixed production.

[0146] Scenario for energy storage pouch battery production lines: Adaptable to 500-1000Ah large energy storage pouch batteries (size 500×300×25mm, weight ≥5kg). The core requirements of the production line are to balance gripping stability and safety, and to withstand clamping off-center loads. This system's drive adjustment module enables "adaptive compensation function." When the pressure acquisition module detects a multi-point pressure difference ≥3N on the clamping surface, it automatically adjusts the clamping mechanism posture (adjustment angle ≤0.5°) and differentiates the pressure in each area. The pressure acquisition module uses 20 distributed sensors (spatial point spacing 10mm) to fully cover the clamping surface of large-size batteries, avoiding local pressure concentration. During integration, a modular installation method is adopted, directly fixed to the existing gripping mechanism beam. The modification cycle is only 6 hours, and the modification cost is 80,000 yuan, which is only 15% of the cost of building a new dedicated production line.

[0147] Scenario for consumer electronics pouch battery production lines: Adapted to 1-10Ah miniaturized pouch batteries (3-5mm thickness, 0.1mm aluminum-plastic film thickness), with a production line gripping frequency of 8 times / second, requiring lightweight integration and no mechanical interference. This system's control unit adopts a lightweight architecture of "MCU + dedicated signal processing chip," with an overall weight ≤2kg; the deformation detection module uses a 0.5mm diameter micro-fiber optic probe to avoid scratching the thin aluminum-plastic film; the preset safe initial value of the drive adjustment module is adjusted to 1 / 4 of the lower limit of the safe pressure range (e.g., ≤1.25N when the safe pressure range is 5-10N), and the back-avoidance distance is controlled within 0.5-1mm, precisely adapting to the fragile structure of small batteries.

[0148] The system works as follows: During the gripping and initiation phase, the drive mechanism starts according to the baseline parameters in the data storage module, and the pressure acquisition module and deformation detection module simultaneously begin data acquisition. During the dynamic adaptation and adjustment phase, the control unit processes the data from both modules using a preset fusion algorithm. When the pressure approaches 80% of the safety threshold, the system dynamically matches the drive parameters based on the pressure rise rate. If the contact speed is too fast, the speed is reduced to 30% of the baseline speed, and the stroke buffer amplitude is increased simultaneously. When the deformation data shows an upward trend of more than 0.01mm, predictive adjustment is immediately initiated, fine-tuning the clamping pressure with a precision of 0.05N, while simultaneously slowing down the stroke adjustment rate. During the closed-loop stabilization phase, the control unit continuously compares the pressure and deformation data with the standard threshold, dynamically correcting the drive parameters until the battery is smoothly gripped and transferred to the target position, maintaining a balance between pressure and drive state throughout the process.

[0149] This system solves the problems of insufficient dynamic adaptation and damage hysteresis suppression in existing technologies by using pressure-deformation dual signal linkage and predictive adjustment. It achieves flexible adaptation and gripping of soft-pack lithium batteries of different specifications, and improves the safety and reliability of the gripping process.

[0150] In the description of this invention, it should be understood that the various forms of processes shown above can be used, with steps reordered, added, or deleted. For example, the steps described in this disclosure can be executed in parallel, sequentially, or in different orders, as long as the desired results of the technical solutions provided in this disclosure can be achieved, and no limitation is imposed herein.

[0151] The above description is merely a preferred embodiment of the present invention and does not constitute a limitation on the scope of protection of this disclosure. Those skilled in the art should understand that various modifications, combinations, sub-combinations, and substitutions can be made according to design requirements and other factors. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this disclosure should be included within the scope of protection of this disclosure.

Claims

1. A flexible, adaptable, independent gripping pressure feedback system for soft-pack lithium batteries, characterized in that, include: The data storage module is used to store the standard deformation threshold, safe pressure range value and driving reference parameters corresponding to the soft pack battery. The pressure acquisition module is used to acquire pressure data of the clamping surface in real time during the gripping process of the soft-pack battery; The deformation detection module is used to collect minute deformation data of the soft-pack battery surface in real time during the soft-pack battery grasping process; The control unit establishes communication connections with the pressure acquisition module, deformation detection module, data storage module, and drive adjustment module, respectively. The control unit processes the received pressure data and deformation data through a preset fusion algorithm, and dynamically generates drive adjustment commands based on the matching result of the pressure data and the safe pressure range value and the changing trend of the deformation data. The drive adjustment commands are fed back by the drive adjustment module when the pressure is close to a preset proportion of the safe pressure range and when the deformation data shows an upward trend of not less than a preset amplitude. When the pressure data exceeds the safe pressure range or the deformation data exceeds the standard deformation threshold, the control unit generates a drive adjustment command and simultaneously starts an emergency buffer program to avoid damage to the pouch battery caused by a sudden failure, thus forming a dual early warning mechanism of pressure and deformation. The drive adjustment module is used to receive and execute the drive adjustment commands of the control unit to adjust the clamping speed, stroke buffer amplitude and clamping pressure to achieve adaptive clamping of the soft-pack battery.

2. The flexible adaptable soft-pack lithium battery independent gripping pressure feedback system according to claim 1, characterized in that, The control unit and the drive adjustment module are integrated and installed on the same mounting body, or directly installed on the housing of the drive adjustment module, so as to shorten the signal transmission path; The pressure acquisition module, deformation detection module and control unit adopt a dual transmission mechanism of industrial Ethernet and pulse signal. The transmission delay of the pressure data, deformation data and drive adjustment command does not exceed the preset delay threshold. The control unit adopts a PLC and embedded chip collaborative architecture to ensure the real-time performance of data processing and command output.

3. The flexible adaptable soft-pack lithium battery independent gripping pressure feedback system according to claim 1, characterized in that, The emergency buffer procedure includes: The control unit controls the drive adjustment module to quickly reduce the clamping pressure to a preset safe initial value, which is no greater than 1 / 3 of the lower limit of the safe pressure range; The control unit synchronously controls the clamping mechanism to move back slightly away from the soft-pack battery, and the distance of the back movement is no more than 2mm. After the pressure data returns to the safe pressure range and the deformation data returns to the standard deformation threshold, the control unit controls the drive adjustment module to execute drive adjustment commands adapted to the current state based on the real-time collected pressure data and deformation data.

4. The flexible adaptable soft-pack lithium battery independent gripping pressure feedback system according to claim 1, characterized in that, The data storage module supports manual updates or automatic iterations of the standard deformation threshold, safe pressure range, and driving reference parameters for different models of pouch batteries. By updating these parameters, it is possible to adapt to pouch batteries of various specifications that have differences in packaging tightness or cell distribution uniformity.

5. The flexible adaptable soft-pack lithium battery independent gripping pressure feedback system according to claim 1, characterized in that, The pressure acquisition module includes distributed pressure sensors, which are evenly arranged across the entire clamping surface of the pouch battery, and the spacing between the sensor acquisition points does not exceed a preset spacing threshold, for synchronous and comprehensive acquisition of pressure data from multiple points on the clamping surface.

6. The flexible adaptable soft-pack lithium battery independent gripping pressure feedback system according to claim 1, characterized in that, The deformation detection module has a detection accuracy of not less than a preset accuracy threshold. Its detection probes are distributed in a distributed manner corresponding to the corners and middle area of ​​the soft-pack battery, which is used to accurately capture the minute deformations at key locations on the surface of the soft-pack battery and form corresponding deformation data.

7. The flexible adaptable soft-pack lithium battery independent gripping pressure feedback system according to claim 1, characterized in that, When the control unit processes pressure data and deformation data through a preset fusion algorithm, the fusion algorithm is constructed based on the matching degree between pressure data and safe pressure range and the rate of change of deformation data, so as to realize the collaborative analysis of pressure-deformation dual signals.

8. The flexible adaptable soft-pack lithium battery independent gripping pressure feedback system according to claim 1, characterized in that, When the pressure data approaches a preset percentage threshold of the safe pressure range, the drive adjustment command controls the drive adjustment module to reduce the clamping speed to a preset percentage of the reference speed corresponding to the drive reference parameter, and simultaneously increases the stroke buffer amplitude to avoid rigid impact between the clamping surface and the soft-pack battery.

9. The flexible adaptable soft-pack lithium battery independent gripping pressure feedback system according to claim 1, characterized in that, When the deformation data shows an upward trend of not less than a preset range, the drive adjustment command controls the drive adjustment module to fine-tune the clamping pressure with a preset pressure adjustment accuracy, and simultaneously slows down the stroke adjustment rate, thereby suppressing irreversible bulging by reverse-directing the deformation trend.

10. The flexible adaptable soft-pack lithium battery independent gripping pressure feedback system according to claim 1, characterized in that, The pressure acquisition module, deformation detection module, control unit, and drive adjustment module are integrated and installed above and to the side of the gripping component of the automated production line gripping mechanism.

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