A smart and flexible assembly process and assembly line for battery module PACK

Abstract

This invention discloses an intelligent flexible assembly process and assembly line for battery module PACKs, comprising the following steps: S1, line changeover adaptation; S101, product determination; S102, model changeover adaptation; S2, battery module production; S201, cell processing; S202, module stacking; S203, PACK processing. This invention is compatible with the assembly of power batteries and energy storage batteries. During product model changeovers, no physical tooling or mechanical structure adjustments are required. Only a new production formula needs to be called in the software, and the carrier can automatically adjust the spacing, speed, and path, achieving zero physical changeover time. It also has a high degree of automation, thus effectively improving assembly efficiency and facilitating practical use.

Description

Technical Field

[0001] This invention relates to the field of battery cell module assembly technology, and in particular to an intelligent flexible assembly process and assembly line for battery module PACK. Background Technology

[0002] With the development of existing new energy technologies, the demand for battery packs is gradually increasing. Among them, modules using square cells as the main cells are the most common and are currently widely used in new energy vehicles, large-scale energy storage power stations and other fields.

[0003] Previously, the assembly process of module PACK assembly lines still involved many manual steps, which often resulted in low assembly efficiency and negatively impacted assembly quality. Furthermore, most existing assembly lines operated on a "dedicated line for a specific purpose" model, exhibiting significant limitations. The production line configuration was relatively fixed: a single line could only produce a few specific models of power battery modules or energy storage battery modules, with fixed equipment layouts and tooling fixtures. When switching between power battery and energy storage battery production or when there were changes to the production process, the line had to be shut down for extended periods for line modifications, fixture replacement, equipment readjustment, and program modifications—a time-consuming and labor-intensive process. Introducing two different production lines would increase investment and maintenance costs. To address these compatibility challenges and high investment costs encountered with previous production lines, designing an intelligent, flexible battery module PACK assembly line that achieves highly efficient and automated assembly and can flexibly adjust to module requirements for line switching has become a problem that needs to be solved by those in the field. Summary of the Invention

[0004] The purpose of this invention is to address the shortcomings mentioned above by providing an intelligent and flexible assembly process and assembly line for battery modules, achieving efficient and automated assembly, and enabling flexible line changes and adjustments according to module requirements.

[0005] To solve the above technical problems, the present invention adopts the following technical solution: an intelligent flexible assembly process for a battery module PACK, comprising the following steps: S1. Cable replacement and adaptation processing; S101. Product Determination: Pre-determine the type of battery module to be manufactured; S102, Changeover and Adaptation: Based on the product type determined in step S100, when switching production types, the corresponding production formula is called through the software, and the assembly line parameters are adjusted to perform the changeover. After the changeover is completed and qualified, the subsequent production process is started. S2. Battery module production: The following processes are performed sequentially; S201, Cell Processing: The entire tray of cells is transported to the cell processing section by AGV trolley. After scanning and OCV testing, NG cells are sorted out and qualified cells are discharged. After polarity adjustment, qualified cells are glued by the roll glue application mechanism or sheet glue application mechanism. After the glue is removed and the cells pass the manual re-inspection, they are transported to the module stacking section. S202, Module Stacking: After the steel strip is pre-embedded manually, the six-axis robot grabs the battery cell, changes pitch, turns and transports it to the upper and lower alternating stacking platform. After extrusion shaping, end plate / side plate installation and steel strip sleeve, the module code is generated by laser marking and the battery cell data is bound. Then, it is transported to the PACK processing section. S203, PACK processing: The magnetic levitation conveyor line transfers the module to the gluing station to complete the gluing of the liquid cooling plate or the box. After passing the visual inspection, the module is assembled into the box and locked and fixed. The pole is located by visual addressing, and after laser cleaning, the CCS component is installed and the PACK code is bound. The bus is fixed by a servo variable pitch clamping mechanism. After laser welding, the weld is inspected and qualified, and the product is completed and off the production line.

[0006] A smart flexible assembly line for battery module packs includes: Cell processing section, module stacking section, PACK processing section; The cell processing section includes a cell testing and unpacking module, a transfer mechanism, a circular conveyor line, a roll adhesive application mechanism, and a sheet adhesive application mechanism. These mechanisms are used to sequentially perform feeding tests, non-conforming sorting, polarity adjustment, adhesive application and peeling tests, and pre-stacking of the cells to complete the cell pre-processing operation. The module stacking section includes a module stacking mechanism, a module extrusion mechanism, a module marking mechanism, a module box entry mechanism, a pre-embedded steel strip workstation, and a magnetic levitation conveyor line, which are used to sequentially perform steel strip pre-embedding, cell stacking and extrusion, end plate and side plate assembly, pressing and measuring distance sleeve steel strip, data binding and uploading, and marking and binding code storage. The PACK processing section includes a liquid cooling plate gluing workstation, a module fixing workstation, an addressing and cleaning workstation, an assembly and binding workstation, and a laser welding mechanism. These are used to sequentially perform gluing and gluing inspection on the PACK, module placement and locking, cell terminal cleaning, CCS component assembly and binding, busbar welding and post-weld inspection, and complete the finished product offline.

[0007] Furthermore, the cell testing and disassembly module includes a first robotic arm, a cell loading assembly, and a testing and disassembly assembly; The battery cell feeding assembly includes a first mounting base disposed at the moving end of the first robotic arm, a first support disposed on the first mounting base, a pressure plate cylinder disposed vertically on the first support, and a plurality of first rotary cylinders that can slide up and down disposed at the bottom of the first support. A compression spring is disposed between each first rotary cylinder and the first support, and an anti-fall gripper is disposed at the moving end of each first rotary cylinder. The detection and disassembly assembly includes a second support disposed at the moving end of the first robotic arm. A first drive cylinder is disposed at the bottom of the second support. Multiple empty disk handling components are also disposed on the second support. The first drive cylinder has at least one moving end, and an OCV test probe is disposed on its moving end. A vision positioning part is disposed on the second support. A pitch-changing component is also disposed on the second support. A support plate is disposed at the moving end of the pitch-changing component. At least one first barcode scanner is disposed on the support plate.

[0008] Furthermore, the roll adhesive application mechanism includes a first worktable, on which an X-axis servo slide is provided, a Z-axis servo slide is provided at the moving end of the X-axis servo slide, a torque component is provided at the moving end of the Z-axis servo slide, an air shaft is provided at the moving end of the torque component, a roll of material is provided on the air shaft, and a servo drive component, at least one guide shaft, two rotatably adjustable waste rolls, and a strip clamping component are also provided at the moving end of the torque component. The sheet adhesive application mechanism includes a base, a hopper component disposed on the base, a first drive unit, a feeding component, a secondary positioning component, an adhesive application component, and a release paper peeling component; The hopper component has two sets of hopper stations for loading film, and the two sets of hopper stations can alternately supply material to the feeding component; The first driving unit is used to drive the feeding component and the adhesive application component to move along their X-axis and Y-axis directions; The feeding component is used to grab the film at the hopper station and move it to the secondary positioning component; The secondary positioning component is used to perform secondary positioning of the film on it; The release paper tearing component is used to tear off the release paper from the film on it; The adhesive applicator is used to pick up the adhesive sheet from the secondary positioning component, send it to the release paper peeling component for processing, and then attach the processed adhesive sheet to the battery cell.

[0009] Furthermore, the module stacking mechanism includes a second robotic arm, a transfer gripper component, a stacking platform component, a third robotic arm, and a module handling component; The transfer gripper component includes a variable pitch slide table disposed at the moving end of the second robotic arm. The variable pitch slide table has at least one moving end, and a second rotary cylinder is disposed at its moving end. A gripper cylinder is disposed at the moving end of the second rotary cylinder. The stacking platform component includes a platform body on which at least two stacking portions are slidably disposed; The stacking section includes a mounting frame, on which a centering servo motor is mounted. The mounting frame also includes a centering timing belt and a first linear guide rail. The mounting frame also includes two centering plates that can move toward or away from each other. The centering servo motor can work with the centering timing belt and the first linear guide rail to drive the two centering plates toward or away from each other. The mounting frame also includes a second linear guide rail. A second drive unit is provided at the input end of the second linear guide rail. A clamping push block is provided at the moving end of the second linear guide rail. The mounting frame also includes a fixed reference block that cooperates with the clamping push block. A drive unit is provided on the stacking part, and a rack is provided on the platform. The drive unit includes a servo motor provided on the mounting frame. A gear is provided on the rotating shaft of the servo motor. The gear meshes with the rack. The drive unit can cooperate with the rack to drive the stacking part to move and flow between the material picking station of the module handling component and the material loading station of the transfer gripper component. The module handling component includes a third support set at the moving end of the third robotic arm. The third support is provided with a first clamping screw part. The moving end of the first clamping screw part is provided with two oppositely distributed first fixed jaws. The bottom of the third support is provided with a lifting cylinder. The moving end of the lifting cylinder is provided with a first sponge suction cup, and the first sponge suction cup is located at the center of the two first fixed jaws. The third support is also provided with a bottom support component. The bottom support component includes a support rod rotatably mounted on the side wall of the third support, a connecting frame hinged to the support rod, an adjusting block hinged to the side of the connecting frame away from the support rod, and a second driving cylinder vertically mounted on the third support, with the adjusting block located at the moving end of the second driving cylinder. The support rod is also equipped with a detection unit, which is used to detect the rotation state of the support rod.

[0010] Furthermore, the module extrusion mechanism includes a first mounting platform, on which a servo electric cylinder is provided. A fourth support is provided at the moving end of the servo electric cylinder, and a clamping electric cylinder is provided at the moving end of the fourth support. A clamping plate is provided at the moving end of the clamping electric cylinder.

[0011] Furthermore, the module marking mechanism includes a second mounting platform, on which an X-axis moving module is disposed, a Y-axis moving module is disposed at the moving end of the X-axis moving module, a Z-axis moving module is disposed at the moving end of the Y-axis moving module, and a second barcode scanner and marking galvanometer are disposed at the moving end of the Z-axis moving module.

[0012] Furthermore, the module loading mechanism includes a fourth robotic arm, a fifth support is provided at the moving end of the fourth robotic arm, a second clamping screw is provided on the fifth support, a second gripper is provided at the moving end of the second clamping screw, and a second sponge suction cup is also provided on the fifth support.

[0013] Furthermore, the laser welding mechanism includes a fifth robotic arm, a pressure head adjustment unit, a pressure head component, and a second worktable; The fifth robotic arm is provided with a welding section at its moving end; The pressure head adjustment section is used to drive the pressure head component to move along its X-axis and Y-axis directions.

[0014] Furthermore, the pressure head component includes a second mounting base disposed at the moving end of the pressure head adjustment section. A pressure cylinder is disposed on the second mounting base. A servo slide is disposed at the moving end of the pressure cylinder. The servo slide has multiple moving parts, and a mounting plate is disposed on each moving part. The servo slide can drive the mounting plates on each moving part to move accordingly and change their spacing. A welding pressure head and a nitrogen protection device are disposed on the mounting plate. The servo slide is also equipped with a laser rangefinder; The nitrogen protection device includes a connection port disposed on and communicating with the welding pressure head, and the welding pressure head is also provided with an annular guide groove, the output end of the connection port being connected to the guide groove.

[0015] The beneficial effects of this invention are reflected in: (1) The present invention is compatible with the module assembly of power batteries and energy storage batteries. When changing the product, there is no need to change any physical tooling or adjust the mechanical structure. Only the new production formula needs to be called in the software, and the vehicle can automatically adjust the spacing, speed and path to achieve zero physical changeover time, which is convenient for actual use.

[0016] (2) In this invention, the cells are first processed in the cell processing section, which performs feeding tests, non-conforming sorting, polarity adjustment, adhesive application and peeling detection, and pre-stacking to complete the cell pre-processing operation. Then, the module stacking section performs steel strip pre-embedding, cell stacking and extrusion, end plate and side plate assembly, pressing and measuring the distance and sleeve of steel strip, data binding and uploading, and code binding and storage on the cells processed in the previous step. Finally, the PACK processing section performs adhesive application and adhesive application detection, module boxing and locking, cell terminal cleaning, CCS component assembly and code binding, busbar welding and post-weld inspection to complete the finished product. This enables efficient assembly, welding and production assembly of power modules or energy storage modules and PACK battery packs. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the cell processing section in this invention; Figure 2 This is a schematic diagram of the module stacking section in this invention; Figure 3 This is a schematic diagram of the PACK processing section in this invention; Figure 4 This is a schematic diagram of the battery cell feeding assembly setup in this invention; Figure 5 This is a schematic diagram of the battery cell feeding assembly in this invention; Figure 6 This is a schematic diagram of the structure of the detection and disassembly assembly in this invention; Figure 7 This is a bottom view of the detection and disassembly assembly in this invention; Figure 8 This is a schematic diagram of the roll adhesive application mechanism in this invention; Figure 9 This is a schematic diagram of the sheet adhesive application mechanism in this invention; Figure 10 This is a schematic diagram of the module stacking mechanism in this invention; Figure 11 This is a schematic diagram of the transfer gripper component in this invention; Figure 12 This is a schematic diagram of the stacking platform component in this invention; Figure 13 This is a partial schematic diagram of the stacked portion in the present invention; Figure 14 This is a schematic diagram of the module handling component in this invention; Figure 15 In this invention Figure 14 A magnified view of part A shown; Figure 16 This is a schematic diagram of the module extrusion mechanism in this invention; Figure 17 This is a schematic diagram of the module marking mechanism in this invention; Figure 18 This is a schematic diagram of the module loading mechanism in this invention (excluding the fourth robotic arm). Figure 19 This is a schematic diagram of the laser welding mechanism in this invention; Figure 20 This is a schematic diagram of the pressure head component in this invention; Figure 21 This is a schematic diagram of the nitrogen protection device in this invention; Figure 22 This is a side sectional view of the nitrogen protection device in this invention; Figure 23 This is a schematic diagram of the first line-changing process of the present invention; Figure 24 This is a schematic diagram of the second line-changing process of the present invention; Figure 25 This is a schematic diagram of the third line-changing process of the present invention.

[0018] In the picture: 1. Cell Inspection and Disassembly Module; 101. First Robotic Arm; 102. Cell Loading Assembly; 1021. First Mounting Base; 1022. First Support; 1023. Pressure Plate Cylinder; 1024. First Rotary Cylinder; 1025. Compression Spring; 1026. Anti-fall Gripper; 103. Inspection and Disassembly Assembly; 1031. Second Support; 1032. First Drive Cylinder; 1033. Empty Plate Handling Component; 1034. OCV Test Probe; 1035. Vision Positioning Unit; 1036. Pitch Variable Component; 1037. First Barcode Scanner; 2. Transfer Mechanism; 3. Circular Conveyor Line; 4. Roll Material Adhesive Applying Mechanism; 401. First Worktable; 402. X-axis Servo Slide; 403. Z-axis Servo Slide; 404. Torque Components; 405, Air shaft; 406, Material roll; 407, Servo drive component; 408, Guide shaft; 409, Waste roll; 410, Material strip clamping component; 5, Sheet adhesive applicator; 501, Base; 502, Hopper component; 503, First drive unit; 504, Feeding component; 505, Secondary positioning component; 506, Adhesive applicator; 507, Release paper peeling component; 6, Module stacking mechanism; 601, Second robotic arm; 602, Transfer gripper component; 6021, Variable pitch slide; 6022, Second rotary cylinder; 6023, Gripper cylinder; 603, Stacking platform component; 6031, Platform body; 6032, Stacking section; 6032a, Mounting frame; 6032b, Centering servo motor; 6032c. Centering synchronous belt; 6032d, first linear guide rail; 6032e, centering plate; 6032f, second linear guide rail; 6032g, second drive unit; 6032h, clamping push block; 6032i, fixed reference block; 6032j, rack; 6032k, drive unit; 604, third robotic arm; 605, module handling component; 6051, third support; 6052, first clamping screw; 6053, first fixed gripper; 6054, first sponge suction cup; 6055, bottom support component; 6055a, support rod; 6055b, connecting frame; 6055c, adjusting block; 6055d, second drive cylinder; 6055e, detection unit; 7, module extrusion mechanism; 701, first mounting platform; 70 2. Servo electric cylinder; 703. Fourth support; 704. Clamping electric cylinder; 705. Clamping plate; 8. Module marking mechanism; 801. Second mounting platform; 802. X-axis moving module; 803. Y-axis moving module; 804. Z-axis moving module; 805. Second barcode scanner; 806. Marking galvanometer; 9. Module box loading mechanism; 901. Fifth support; 902. Second clamping screw; 903. Second gripper; 904. Second sponge suction cup; 10. Embedded steel strip workstation; 11. Magnetic levitation conveyor line; 12. Liquid-cooled plate gluing workstation; 13. Module fixing workstation; 14. Addressing and cleaning workstation; 15. Assembly and binding workstation; 16. Laser welding mechanism; 1601. Fifth robotic arm; 1602. Welding section;1603, Pressure head adjustment unit; 1604, Pressure head component; 1604a, Second mounting base; 1604b, Lowering cylinder; 1604c, Servo slide; 1604d, Mounting support plate; 1604e, Laser ranging unit; 1604f, Welding pressure head; 1604g, Connection port; 1606, Second worktable. Detailed Implementation

[0019] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. Unless otherwise specified, the embodiments and features in the embodiments of this application can be combined with each other. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0020] A smart flexible assembly process for a battery module PACK includes the following steps: S1. Cable replacement and adaptation processing; S101. Product Determination: Pre-determine the type of battery module to be manufactured; S102, Changeover and Adaptation: Based on the product type determined in step S101, when switching production types, the corresponding production formula is called through the software, and the assembly line parameters are adjusted to perform the changeover. After the changeover is completed and qualified, the subsequent production process is started. S2. Battery module production: The following processes are performed sequentially; S201, Cell Processing: The entire tray of cells is transported to the cell processing section by AGV trolley. After scanning and OCV testing, NG cells are sorted out and qualified cells are discharged. After polarity adjustment, qualified cells are glued by the roll glue application mechanism or sheet glue application mechanism. After the glue is removed and the cells pass the manual re-inspection, they are transported to the module stacking section. S202, Module Stacking: After the steel strip is pre-embedded manually, the six-axis robot grabs the battery cell, changes pitch, turns and transports it to the upper and lower alternating stacking platform. After extrusion shaping, end plate / side plate installation and steel strip sleeve, the module code is generated by laser marking and the battery cell data is bound. Then, it is transported to the PACK processing section. S203, PACK processing: The magnetic levitation conveyor line transfers the module to the gluing station to complete the gluing of the liquid cooling plate or the box. After passing the visual inspection, the module is assembled into the box and locked and fixed. The pole is located by visual addressing, and after laser cleaning, the CCS component is installed and the PACK code is bound. The bus is fixed by a servo variable pitch clamping mechanism. After laser welding, the weld is inspected and qualified, and the product is completed and off the production line.

[0021] First embodiment: Please see Figure 23A battery module PACK intelligent flexible assembly process includes the following steps: S1. Cable replacement and adaptation: S101. Product Determination: The product to be manufactured is clearly defined as a power battery module, with no need for liquid cooling plate assembly, and is compatible with... Figure 23 Core process route.

[0022] S102, Type conversion adaptation: When switching production types, the corresponding production formula for the power battery module is called through the industrial control computer, without the need to change physical tooling or adjust the settings and positions of the mechanical structure. Automatically load core parameters, including but not limited to: cell grabbing path and pitch parameters, polarity adjustment angle, roll / sheet adhesive application position and pressure, laser welding power and focal length, magnetic levitation conveyor line stopping point, OCV test voltage threshold, weld inspection judgment criteria, etc.

[0023] The system automatically verifies the integrity and compatibility of the loaded parameters. After confirming that the model change is qualified, it starts the subsequent production process.

[0024] S2, Power Battery Module Production: S201 AGV trolley automatically transfers whole pallets of packaged battery cells from the battery cell storage area to the battery cell processing section loading position, and the roller conveyor line transfers the battery cells to the testing position; S202, the conveyor line transfers the battery cell to the OCV scanning test station. The first robotic arm 101 moves the detection and disassembly assembly 103. After the vision positioning unit 1035 completes the positioning of the battery cell, the first barcode scanner 1037 automatically scans the QR code of the battery cell. The first drive cylinder 1032 drives the OCV test probe 1034 to perform performance testing on the battery cell. The test information is bound to the battery cell code, stored in the local industrial control computer, and uploaded to the MES system. S203. After the test is completed, the three types of unqualified cells, namely NG in barcode scanning, NG in performance, and NG in test, are picked up by the cell detection and disassembly module 1 and sent to the buffer conveyor line. When the material is full, the equipment will sound and light alarm to prompt manual material collection. S204. After the first layer of battery cells passes the test, the battery cell detection and disassembly module 1 simultaneously grabs 5 battery cells and places them in the double-speed chain tray. S205. After the first layer of battery cells is picked up and put on the line, the empty pallet transport component 1033 of the battery cell detection and unpacking module 1 works with the first robotic arm 101 to complete the unpacking and stacking of empty pallets. S206. The transfer mechanism 2 automatically grabs 5 battery cells from the double-speed chain tray. Each battery cell is rotated independently by the first rotary cylinder of its battery cell feeding component. After the polarity adjustment is completed according to the system grouping requirements, the cells are put back into the battery cell tray. S207. The conveyor line transfers the battery cells to the roll adhesive application mechanism 4. The X-axis and Z-axis servo slides work together to drive the roll of material to complete the automatic application of strip adhesive. S208, the conveyor line transfers the battery cell to the sheet adhesive applicator 5. The feeding part 504 grabs the adhesive sheet in the hopper and positions it to the secondary positioning part 505. The release paper tearing part 507 tears off the release paper and after passing the inspection, the adhesive applicator 506 attaches the adhesive sheet to the large surface of the battery cell. S209, The conveyor line transfers the battery cell to the top adhesive-removing station, and the motion mechanism drives the adhesive-removing mechanism to peel off the release paper from the PC sheet; S210, the conveyor line transfers the battery cells to the NG manual processing station. The visual inspection agency takes pictures to inspect the peeling effect. If the peeling is not done properly or the peeling is not qualified, it is handled manually. After the re-inspection is qualified, it is released. S211. After the battery cell adhesive is applied, the six-axis robot picks up the battery cell and places it onto the stacking platform component 603 to complete the pre-stacking. S212. The steel strip is manually removed from the pre-embedded steel strip workstation 10 and pre-embedded into the tooling pallet; S213, a six-axis robot, in conjunction with a transfer gripper component 602, picks up pre-stacked battery cells from a double-speed chain tray and adjusts the spacing between the battery cells via a variable-pitch slide table 6021; S214. The six-axis robot drives the transfer gripper component 602 to transfer the variable-pitch battery cell into the stacking part 6032 of the stacking platform component 603. S215, the centering servo motor 6032b of the stacking part 6032 works with the centering synchronous belt 6032c to drive the centering plate 6032e to center the battery cell. The second drive part 6032g drives the clamping push block 6032h to press the battery cell to the fixed reference block 6032i, completing the extrusion and shaping of the battery cell module. S216, the six-axis robot, together with the module handling component 605, clamps the module with the first fixed gripper 6053, the first sponge suction cup 6054 adsorbs the upper surface of the battery cell, and the bottom support component 6055 provides bottom protection, and transfers the module into the module extrusion section tray. S217, the magnetic levitation conveyor line 11 transfers the module to the manual end plate / side plate installation position, automatically stops and locks the tooling plate; S218. Manually install the end plates and side plates to ensure proper assembly; S219. When the operator presses the operation button, the servo electric cylinder 702 of the module extrusion mechanism 7 drives the clamping plate 705 to press the module along the length of the module and measure the distance simultaneously. Under overpressure conditions, the operator lifts the lower steel strip from the clamp and puts it on the lower part of the module, then puts on the upper steel strip. After binding the servo extrusion pressure with the module code, the information is uploaded to the MES system. S220. After the upper and lower steel strips are installed, the module extrusion mechanism 7 is released and retracted, and the tooling plate is automatically transferred to the next station. S221, the magnetic levitation conveyor line 11 transfers the module to the module marking mechanism 8 and stops automatically; S222, The scanning system of the module marking mechanism 8 scans the cell code to generate a unique module code. The Z-axis moving module 804 drives the marking mirror 806 to mark the code on the end plate, completing the binding and storage of the module code and cell data. S223. After the coding is completed, the mechanism is reset, and the magnetic levitation conveyor line 11 transfers the module to the PACK processing section. S224, the magnetic levitation conveyor line 11 transfers the module to the box gluing station, stops automatically, and the barcode scanner automatically scans the box QR code. S225, a six-axis robot, drives a vision addressing camera to locate the MARK point of the box, completes the glue application of the box according to the preset program, and uploads the glue application information and the box code to the MES system. The S226 six-axis robot drives a vision inspection camera to take pictures of the glue application trajectory. After confirming that there is no glue leakage or breakage, the magnetic levitation line transfers the PACK to the box-in station. S227, the magnetic levitation conveyor line 11 conveys the pallet to the module boxing mechanism 9, and the tooling plate clamping mechanism automatically opens; The S228 six-axis robot drives a vision inspection camera to take pictures of the screw hole locations inside the box, and picks up the module from the module tray and accurately puts it into the box. S229, the magnetic levitation conveyor line 11 transfers the PACK loaded with modules to the module fixed workstation 13 and stops automatically; S230: Manually scan the box code with a barcode scanner, and then use a torque gun to lock and fix the module to the box. After tightening, press the release button. S231, the magnetic levitation conveyor line 11 transfers the PACK to the addressing and cleaning workstation 14, where an automatic barcode scanner scans the PACK code. The S232 six-axis robot drives the vision addressing camera to sequentially complete the cell electrode post photography and addressing, and the addressing information is bound and stored with the tooling board; then it drives the laser cleaning head to complete the electrode post laser cleaning, and the cleaning information is uploaded to the MES system. S233. After cleaning, the magnetic levitation conveyor line 11 will transfer the PACK to the assembly and binding workstation 15. S234. Manually take CCS components from the material cart and assemble them onto the module. Print the PACK barcode using a barcode printer and affix it to the box. Use a handheld barcode scanner to scan the CCS component code and module code to complete the binding, storage, and upload to the MES system. S235. After assembly, the magnetic levitation conveyor line 11 will transfer the PACK to the laser welding mechanism 16 and stop automatically. The barcode scanner will scan the QR code on the box. S236, a six-axis robot drives a vision camera to locate the PACK box Mark point and automatically import the welding trajectory; the pressure head component 1604 with laser rangefinder 1604e presses the manifold and simultaneously completes the automatic focus adjustment; the nitrogen protection device sprays nitrogen in a ring and the smoke extraction and dust removal pipeline works simultaneously. S237, two sets of welding clamping mechanisms work together with welding part 1602 to alternately clamp and weld poles, a six-axis robot drives galvanometer welding head to weld busbars in sequence, and saves the welding power of each point to the local industrial control computer in real time; S238. After welding is completed, the magnetic levitation conveyor line 11 will transfer the PACK to the post-weld inspection station. The gantry mechanism with line scanning CCD system + 3D profilometer will automatically inspect the appearance of the weld. The inspection data and images will be automatically stored and traceable. S239. After passing the inspection, the magnetic levitation conveyor line 11 transfers the PACK to the manual unloading station. The operator uses the KBK clamp to pick up the PACK and place it on the unloading tray, thus completing the production process.

[0025] Working principle: The module is fixed by upper and lower steel strips, and the liquid cooling plate (box) is an integrated box. After the battery cells are stacked, the module fixing steel strips are first pre-embedded in the lower part of the tooling. After the module is squeezed, the upper and lower steel strips are manually lowered and put into the module (as described in step S219). Finally, the fixed module is placed into the liquid cooling plate (box). The assembly process in this first embodiment is a conventional process.

[0026] Second embodiment: Please see Figure 24 A battery module PACK intelligent flexible assembly process includes the following steps: S1. Cable replacement and adaptation processing; S101. Product Determination: The battery module to be produced is determined in advance, and the battery module is selected as an energy storage battery module with a liquid cooling plate. S102, Type Change Adaptation: According to the product type determined in step S101, when switching production types, the corresponding production formula is called through the software. The software calls the corresponding formula and then loads the corresponding parameters, including but not limited to cell gripping pitch, adhesive application position, welding power, etc. After loading, it is confirmed whether the type change is completed. After confirming that the type change is completed and qualified, the subsequent production process is started. S2. For the assembly of energy storage battery modules with liquid cooling plates, the following procedures shall be performed in sequence: S201: The AGV trolley transfers the entire tray of packaged battery cells from the battery cell storage area, completes the battery cell sorting (classifies and discharges battery cells that fail scanning, performance, or testing), the robot picks up qualified battery cells and adjusts the polarity according to the grouping requirements, completes the automatic application of strip and sheet adhesive, and releases the qualified cells after visual inspection of the adhesive application accuracy and trajectory. S202, Grab the battery cells to complete the module pre-stacking, and pre-extrude and shape the pre-stacking modules; S203. Precisely install the module into the liquid cooling plate to ensure that the assembly gap between the module and the liquid cooling plate meets the preset threshold and ensures reliable heat dissipation contact. S204. Press the module along the length of the module and measure the distance simultaneously to ensure the overall dimensional accuracy of the module after it is assembled with the liquid cooling plate. S205. Install steel straps and nylon straps and install side plates to ensure the binding and fixing effect of steel straps and nylon straps on the module, and to ensure that the side plates fit tightly with the module. S206. Apply glue along the mating surfaces of the side panel, module, and liquid cooling plate. After checking for any glue leakage or breakage, release the module. Upload the glue application information along with the module code. S207. Install the remote end plate and lock it in place to ensure the stability of the module end structure; S208. Complete the module polarity test to ensure that the positive and negative terminals are arranged in accordance with the circuit assembly requirements. S209. Weld the joints between the side plate and the module and the liquid cooling plate to strengthen the connection strength and sealing. Nitrogen protection and fume treatment are carried out simultaneously during the welding process. S210. Automatically inspect the appearance of side plate welds, and store and trace the inspection data and images. S211. Position the battery cell terminals and complete laser cleaning to remove the oxide layer on the terminal surface and ensure welding conductivity. S212. Install the CCS component, print and paste the PACK barcode, and bind the CCS component code and module code; S213. Complete the welding of the pole and the busbar. Nitrogen protection and fume treatment are carried out simultaneously during the welding process. S214. Automatically inspect the appearance of the pole weld, and store and trace the inspection data and images. S215. Install and secure the module cover to seal the top of the module and improve structural integrity and protection performance. S216. Install the front end plate and lock it in place to form protection at both ends of the module in conjunction with the remote end plate; S217. Qualified modules are transferred to the off-line station, and the liquid cooling plate is connected to the online line simultaneously. S218. Scan the QR code on the liquid cooling plate to complete the glue application. The glue application information is then linked to the module code and uploaded. The product is then manually removed from the production line.

[0027] Working principle: The difference between the product in the second embodiment and the product in the first embodiment is that the module is fixed by a lower steel strip and an upper nylon strip. Therefore, this process does not require manual pre-embedding of the lower steel strip. However, the box is a split box (the bottom plate and side plate of the box, as well as the front and rear end plates are spliced ​​by laser welding). At the same time as the module is processed, the liquid cooling plate and side plate are pre-treated by applying glue at the glue application station. After the module is placed in the liquid cooling plate, the side plate, end plate, steel strip and nylon strip are installed manually at the side plate installation station. Then it flows into the side plate welding station, where a six-axis robot carrying a galvanometer welding head welds the side plate and end plate to the liquid cooling plate. Finally, the box cover is installed and the box is taken off the production line.

[0028] In addition, compared with the first embodiment, the second embodiment reduces the module marking process and adds a side plate processing station. The difference in the above process is that the module tooling plate and the box tooling plate are mainly controlled by the PLC program to enter the corresponding workstation. Each tooling plate is equipped with an RFID chip, which can record the material information of the current tooling plate. After the equipment identifies and verifies that the material of the tooling plate is correct, the PLC issues instructions to the equipment to process the current product accordingly.

[0029] Third Embodiment Please see Figure 25 A battery module PACK intelligent flexible assembly process includes the following steps: S1. Cable replacement and adaptation processing; S101. Product Determination: The battery module to be produced is determined in advance, and the battery module is selected as an energy storage battery module. S102, Type Change Adaptation: According to the product type determined in step S101, when switching production types, the corresponding production formula is called through the software. The software calls the corresponding formula and then loads the corresponding parameters, including but not limited to cell gripping pitch, adhesive application position, welding power, etc. After loading, it is confirmed whether the type change is completed. After confirming that the type change is completed and qualified, the subsequent production process is started. S2. Assemble the energy storage battery module by performing the following steps in sequence: S201: The AGV trolley transfers the entire tray of packaged battery cells from the battery cell storage area, completes the battery cell sorting (classifies and discharges battery cells that fail scanning, performance, or testing), the robot picks up qualified battery cells and adjusts the polarity according to the grouping requirements, completes the automatic application of strip and sheet adhesive, and releases the qualified cells after visual inspection of the adhesive application accuracy and trajectory. S202: Grab the battery cells to complete module pre-stacking and pre-extrusion shaping, complete module polarity detection, press the module along the length direction and measure distance simultaneously to ensure module dimensional accuracy; S203. Install the side plates and fit the steel strips to ensure that the side plates fit tightly with the module and that the module structure remains neat after the steel strips are fitted. S204. Apply glue along the side panel and the bonding surface of the module. After checking for no glue leakage or breakage, release the module. Upload the glue application information along with the module code. S205. Scan the cell code to generate the module code, engrave the code on the end board and bind the data to the MES system; accurately place the module into the PACK box, lock and fix it, and bind the box code and module code; S206. Complete the inter-module potting, ensuring that the gaps between modules are filled evenly and without any air bubbles. Upload the potting information and module code to the MES system. S207. Position the cell terminals and complete laser cleaning to remove the oxide layer on the terminal surface; install the CCS assembly and print and affix the PACK barcode, binding the CCS assembly code and module code. S208. Complete the welding of the pole and busbar, and simultaneously perform nitrogen protection and fume treatment; automatically inspect the appearance of the weld, and store and trace the inspection data and images. S209. Qualified modules are transferred to the off-line workstation, and the liquid cooling plate is connected to the online workstation simultaneously. S210. Scan the QR code on the liquid cooling plate to complete the glue application. The glue application information is then linked to the module code and uploaded. The product is then manually removed from the production line.

[0030] Working principle: The product in the third embodiment has the same module installation form as the product in the second embodiment, and the box is also a split box. However, the box in the third embodiment is screw-locked, which is different from the side plate welding form of the second embodiment. In addition, a process of potting glue between modules has been added to this process. This process is also controlled by PLC to enter the tooling plate into the corresponding workstation and perform corresponding processing actions on the product. This process is used to automatically assemble the energy storage battery module.

[0031] The main difference between the three processes mentioned above lies in the different fixing methods and outer casing styles of the power battery module and the energy storage battery module. Therefore, different workstations and processing sequences are required to ensure compatibility with different products.

[0032] Beneficial effects: This assembly process adapts to different product conditions, making it compatible with the assembly of power batteries and energy storage batteries. When changing products, there is no need to replace any physical tooling or adjust the mechanical structure. Only the new production formula needs to be called in the software, and the carrier can automatically adjust the spacing, speed and path. No additional adjustments to the equipment position and type are required to adapt, achieving zero physical changeover time for practical use.

[0033] Please see Figure 1-22The present invention also discloses an intelligent flexible assembly line for battery modules, including a cell processing section, a module stacking section, and a PACK processing section. The cell processing section includes a cell detection and unpacking module 1, a transfer mechanism 2, a ring conveyor line 3, a roll adhesive application mechanism 4, and a sheet adhesive application mechanism 5.

[0034] The module stacking section includes a module stacking mechanism 6, a module extrusion mechanism 7, a module marking mechanism 8, a module box entry mechanism 9, a pre-embedded steel strip workstation 10, and a magnetic levitation conveyor line 11. The PACK processing section includes a liquid-cooled plate gluing workstation 12, a module fixing workstation 13, an addressing and cleaning workstation 14, an assembly and binding workstation 15, and a laser welding mechanism 16.

[0035] In practice, the process begins with the cell processing section, which sequentially performs loading tests, sorting of defective cells, polarity adjustment, adhesive application and removal checks, and pre-stacking. This pre-processing is completed in the module stacking section. Subsequently, the module stacking section performs steel strip pre-embedding, cell stacking and extrusion, end plate and side plate assembly, pressing and measuring the steel strip, data binding and uploading, and coding and storage on the pre-processed cells. Finally, the PACK processing section sequentially performs adhesive application and adhesive application checks, module placement and locking, cell terminal cleaning, CCS component assembly and coding, busbar welding and post-weld inspection, ultimately completing the production line assembly of the finished product. This enables efficient assembly and welding of power modules or energy storage modules and the production and assembly of PACK battery packs, facilitating practical use.

[0036] In one embodiment, the cell testing and disassembly module 1 includes a first robotic arm 101, a cell loading assembly 102, and a testing and disassembly assembly 103. The first robotic arm 101 is placed in a corresponding location via a support base. The cell loading assembly 102 includes a first mounting base 1021 attached to the moving end of the first robotic arm 101. A first support 1022 is mounted on the first mounting base 1021. A pressure plate cylinder 1023 is vertically mounted on the first support 1022. A variable pitch cylinder is also mounted at the bottom of the first support 1022. The variable pitch cylinder has multiple moving parts, and a first rotary cylinder 1024 is slidably mounted on each moving part. A compression spring 1025 is vertically mounted between each first rotary cylinder 1024 and each moving part. A fall protection gripper 1026 is mounted at the moving end of each first rotary cylinder 1024.

[0037] In specific implementation, the first robotic arm 101 can drive the battery cell feeding component 102 to move in multiple directions and pick up materials. When in use, the first robotic arm 101 can drive the battery cell feeding component 102 to approach the battery cell to be picked up located in the material tray. Then, the pressure plate cylinder 1023 works, and its moving end extends and retracts to press the material tray to ensure that the picking process is stable and reliable. Then, the pitch cylinder controls the first rotary cylinder 1024 located on each of its moving parts to move to correspond to the corresponding battery cell. Then, the power unit of the anti-fall gripper 1026 drives the gripper to perform a gripping movement to clamp the corresponding battery cell. After the battery cell is clamped, the pitch cylinder works to widen the distance between the corresponding battery cells on each anti-fall gripper 1026. Finally, the action of the first rotary cylinder 1024 realizes the change from the long side parallel state to the short side parallel state, so as to facilitate the feeding to the corresponding conveyor line.

[0038] In one embodiment, the detection tray removal assembly 103 includes a second support 1031 mounted on the moving end of the first robotic arm 101. A first drive cylinder 1032 is mounted on the bottom of the second support 1031. A plurality of empty tray handling components 1033 are also configured on the second support 1031. The first drive cylinder 1032 has at least one moving end, and an OCV test probe 1034 is mounted on its moving end. A vision positioning unit 1035 is mounted on the second support 1031. The vision positioning unit 1035 may be composed of a vision inspection camera and a light source. A pitch-changing component 1036 is also mounted on the second support 1031. A plate is mounted at the moving end of the pitch-changing component 1036, and at least one first barcode scanner 1037 is mounted on the plate.

[0039] The empty disk transport component 1033 mentioned above can be composed of a lifting cylinder and a clamping cylinder.

[0040] In practice, the conveyor line transports the battery cell to the OCV scanning test station. At this time, the position of the battery cell is first visually positioned by the vision positioning unit 1035. Then, the first robotic arm 101 drives the detection and disassembly assembly 103 to move to the position where the detection and disassembly assembly 103 corresponds to the battery cell. Then, the first barcode scanner 1037 automatically scans the QR code of the corresponding battery cell. Finally, the first drive cylinder 1032 drives the OCV test probe 1034 to move and perform OCV testing on the corresponding battery cell. The test information is bound to the battery cell, stored in the local industrial control computer, and uploaded to the MES system.

[0041] After the inspection is completed, the empty disk transport component 1033 can be driven to work in conjunction with the first robotic arm 101 to transport the corresponding empty disk.

[0042] In one embodiment, the transfer mechanism 2 has the same structure as the battery cell loading assembly 102. It is used to transfer the tested battery cell to the circular conveyor line 3. The circular conveyor line 3 can sequentially transport the battery cell in a circular manner to the corresponding workstations of the roll adhesive application mechanism 4, the sheet adhesive application mechanism 5, and the module stacking mechanism 6, thereby effectively improving the battery cell conveying speed and increasing work efficiency.

[0043] In one embodiment, the roll adhesive applicator 4 includes a first worktable 401, an X-axis servo slide 402 mounted on the first worktable 401, a Z-axis servo slide 403 mounted at the moving end of the X-axis servo slide 402, a torque component 404 mounted at the moving end of the Z-axis servo slide 403, an air shaft 405 mounted at the moving end of the torque component 404, a roll of material 406 detachably sleeved on the air shaft 405, and a servo drive component 407, at least one guide shaft 408, two rotatably adjustable waste rolls 409, and a strip clamping component 410, all located at the moving end of the torque component 404.

[0044] In practice, the operator can install the material roll 406 on the air shaft 405. After the air shaft 405 is ventilated, the material roll 406 can be fixed. Then, the operator passes the material strip on the material roll 406 through each guide shaft 408 and the material strip clamping component 410 and fixes the end to the waste roll 409. Then, the servo drive component 407 drives the material strip to rotate, thereby realizing the feeding action of the film. When the film is in place, the Z-axis servo slide 403 drives it to descend, and at the same time, the X-axis servo slide 402 cooperates to move, thereby realizing the application of the material strip to the surface of the battery cell and completing the application of the strip material.

[0045] In one embodiment, the sheet adhesive applicator 5 includes a base 501, a hopper component 502 disposed on the base 501, a first drive unit 503, a feeding component 504, a secondary positioning component 505, an adhesive applicator 506, and a release paper peeling component 507.

[0046] In specific implementation, the hopper component 502 has two sets of hopper stations for loading film, and the two sets of hopper stations can alternately supply material to the feeding component 504. The first drive unit 503 is used to drive the feeding component 504 and the adhesive application component 506 to move along their X-axis and Y-axis directions. The feeding component 504 is used to grab the film at the hopper station and move it to the secondary positioning component 505. The secondary positioning component 505 is used to perform secondary positioning on the film. The release paper peeling component 507 is used to peel off the release paper on the film. The adhesive application component 506 is used to grab the film from the secondary positioning component 505, send it to the release paper peeling component 507 for processing, and attach the processed film to the battery cell, thereby realizing the application of sheet material.

[0047] In one embodiment, the module stacking mechanism 6 includes a second robotic arm 601, a transfer gripper component 602, a stacking platform component 603, a third robotic arm 604, and a module handling component 605.

[0048] The transfer gripper component 602 includes a variable pitch slide 6021 installed at the moving end of the second robotic arm 601. The variable pitch slide 6021 has at least one moving end, and a second rotary cylinder 6022 is installed at its moving end. A gripper cylinder 6023 is provided at the moving end of the second rotary cylinder 6022.

[0049] In practice, the second robotic arm 601 drives the transfer gripper component 602 to move in multiple directions and approach the corresponding battery cell on the battery cell conveying line. Then, the variable pitch slide 6021 drives the corresponding gripper cylinder 6023 to approach and clamp the corresponding battery cell. Subsequently, the second rotary cylinder 6022 drives the gripper cylinder 6023 to rotate 90 degrees, thereby changing the battery cell from a parallel state on the long side to a parallel state on the short side. Finally, the variable pitch slide 6021 moves to reduce the center distance of the battery cells, thereby facilitating the transfer of the clamped battery cell to the stacking platform component 603.

[0050] In one embodiment, the stacking platform component 603 includes a platform body 6031, on which at least two stacking portions 6032 are slidably disposed. Each stacking portion 6032 includes a mounting frame 6032a, on which a centering servo motor 6032b is mounted. The mounting frame 6032a also includes a centering timing belt 6032c and a first linear guide rail 6032d. The mounting frame 6032a further includes two centering plates 6032e that can move towards or away from each other. Specifically, the centering plates 6032e are slidably mounted on the first linear guide rail 6032d, and the centering servo motor 6032b can cooperate with the centering timing belt 6032c and the first linear guide rail 6032d. The d drives the two centering plates 6032e to move closer or further apart. A second linear guide rail 6032f is also installed on the mounting frame 6032a. A second drive unit 6032g is installed at the input end of the second linear guide rail 6032f. A clamping push block 6032h is installed at the moving end of the second linear guide rail 6032f. A fixed reference block 6032i that cooperates with the clamping push block 6032h is also installed on the mounting frame 6032a. A drive unit 6032k is installed on the mounting frame 6032a. A rack 6032j is installed laterally on the platform 6031. The drive unit 6032k includes a servo motor installed on the mounting frame 6032a. A gear is provided on the shaft of the servo motor. The gear meshes with the rack 6032j.

[0051] In specific implementation, the drive unit 6032k can cooperate with the rack 6032j to drive the stacking part 6032 to move and flow between the picking station of the module handling part 605 and the loading station of the transfer gripper part 602. Specifically, the stacking part 6032 can first move to the loading station of the transfer gripper part 602. Then, the transfer gripper part 602 places each battery cell adjusted to a suitable angle between the corresponding two centering plates 6032e on the mounting frame 6032a. Then, the two centering plates 6032e are controlled to move closer to each other, thereby centering the battery cells between them. After centering, the second drive unit 6032g cooperates with the second linear guide rail 6032f to drive the clamping push block 6032h to move along its X-axis direction, thereby moving each centered battery cell closer to the fixed reference block 6032i, thereby ensuring that all battery cells are on the same reference plane and in a clamped state.

[0052] In one embodiment, the module handling component 605 includes a third support 6051 installed at the moving end of the third robotic arm 604. The third support 6051 is provided with a first clamping screw part 6052. Two first fixed grippers 6053 are installed at the moving end of the first clamping screw part 6052. A lifting cylinder (not shown) is installed at the bottom of the third support 6051. A first sponge suction cup 6054 is installed at the moving end of the lifting cylinder, and the first sponge suction cup 6054 is located at the center of the two first fixed grippers 6053. The third support 6051 is also provided with a bottom support component 6055.

[0053] In practice, the first clamping screw 6052 can drive the two first fixed grippers 6053 to move closer or further apart. After the modules are stacked, the stacking platform 603 releases the corresponding battery cell. Then, the third robotic arm 604 drives the module transporting component 605 to approach the battery cell module. The first clamping screw 6052 drives the two first fixed grippers 6053 to move closer and clamp the battery cell module. After clamping the module, the lifting cylinder works to drive the first sponge suction cup 6054 to descend and adhere to the upper surface of the battery cell. Finally, the third robotic arm 604 can transport the battery cell module.

[0054] Preferably, the bottom support component 6055 includes a support rod 6055a rotatably mounted on the side wall of the third support 6051. A connecting frame 6055b is hinged to the support rod 6055a. An adjusting block 6055c is hinged to the side of the connecting frame 6055b away from the support rod 6055a. A second drive cylinder 6055d is also vertically mounted on the third support 6051. The adjusting block 6055c is mounted at the moving end of the second drive cylinder 6055d. In addition, a detection unit 6055e is also mounted on the support rod 6055a. The detection unit 6055e is used to detect the rotation state of the support rod 6055a.

[0055] In practice, there are two bottom support components 6055, which are positioned opposite each other at the bottom of the third support 6051. After the battery cell module is clamped, the adjusting block 6055c can be driven to rise by the second drive cylinder 6055d. At this time, the connecting frame 6055b drives the support rod 6055a to rotate around the rotational connection point between it and the third support 6051. The support rods 6055a in the two bottom support components 6055 can rotate to the bottom of the battery cell module on the side that is closer to each other, thereby preventing the module from falling accidentally.

[0056] In one embodiment, the module extrusion mechanism 7 includes a first mounting platform 701, on which a servo cylinder 702 is vertically mounted. A fourth support 703 is mounted at the moving end of the servo cylinder 702. A clamping cylinder 704 is provided at the moving end of the fourth support 703. A clamping plate 705 is provided at the moving end of the clamping cylinder 704.

[0057] In practice, the first mounting platform 701 drives the fourth support 703 to rise and fall, and the clamping cylinder 704 drives the clamping plate 705 to move, thereby enabling movement and clamping and squeezing of the corresponding battery cell module.

[0058] In one embodiment, the module marking mechanism 8 includes a second mounting platform 801, on which an X-axis moving module 802 is mounted. A Y-axis moving module 803 is mounted at the moving end of the X-axis moving module 802, a Z-axis moving module 804 is mounted at the moving end of the Y-axis moving module 803, and a second barcode scanner 805 and a marking galvanometer 806 are mounted at the moving end of the Z-axis moving module 804.

[0059] In practice, the X-axis moving module 802, the Y-axis moving module 803, and the Z-axis moving module 804 can respectively drive the second barcode scanner 805 and the coding galvanometer 806 to move along their X, Y, and Z axes, thereby enabling scanning and coding of the modules at the corresponding positions.

[0060] In one embodiment, the module loading mechanism 9 includes a fourth robotic arm (not shown in the figure), a fifth support 901 is installed at the moving end of the fourth robotic arm, a second clamping screw 902 is installed on the fifth support 901, a second gripper 903 is installed at the moving end of the second clamping screw 902, and a second sponge suction cup 904 is also installed on the fifth support 901.

[0061] In practice, the fourth robotic arm can drive the module loading mechanism 9 to move to the corresponding module. The second clamping screw 902 then drives the second gripper 903 to move and clamp the module. At this time, the second sponge suction cup 904 can pick up the module to prevent it from falling off the second gripper 903. After clamping, it can be placed in the PACK box. The module loading mechanism 9 can also grab the CVP400 liquid cooling plate into the module line tray, or grab the CVP400 module with the side plate welded into the PACK line tray, so that it can be used flexibly according to the actual situation.

[0062] Preferably, the pre-embedded steel strip workstation 10 consists of a workstation frame, safety light curtain, integrated machine and wire guide ladder, etc., which is used for manual pre-embedding of the lower steel strip.

[0063] Preferably, the magnetic levitation conveyor line 11 includes a line body, a magnetic levitation stator module, a magnetic levitation mover module, a connecting position, a tooling plate, a tooling opening mechanism, and a control assembly, etc., which are used to complete the conveying and assembly operations between the modules.

[0064] Preferably, the liquid-cooled plate gluing workstation 12 includes a six-axis robot system, a gluing system (the gluing equipment mainly consists of a glue supply system, a transfer system, a metering system, and a pipeline package), a vision positioning system, a barcode scanning system, an industrial control computer, a glue receiving mechanism, a control assembly, and a CVP400 gluing mechanism, etc., which is used for gluing the liquid-cooled plate under the PACK package or the side panel of the CVP400 product.

[0065] Preferably, the module fixing workstation 13 consists of a workstation frame, a barcode scanning system, an all-in-one machine, and a cable ladder, which is used to fix the module to the housing by screws manually.

[0066] Preferably, the addressing cleaning workstation 14 comprises an addressing cleaning motion mechanism, a dust collector, a laser, a galvanometer cleaning head, a vision positioning system, a barcode scanning system, and an industrial control computer, which are used for addressing, locating, and cleaning the modules.

[0067] Preferably, the assembly and barcode binding workstation 15 comprises a workstation frame, a vision inspection system, a barcode scanning system, an all-in-one machine, and a barcode printer, etc., for manually assembling busbar components onto modules and manually scanning and binding modules with PACKs. It should be noted that the pre-embedded steel strip workstation 10, the liquid-cooled plate gluing workstation 12, the module fixing workstation 13, the addressing and cleaning workstation 14, and the assembly and binding workstation 15 are all common knowledge in this field. Therefore, their specific structural composition and working principle will not be described in detail in this article. The magnetic levitation conveyor line 11 has the advantages of independent drive, no physical connection, and zero physical changeover time. It can effectively improve positioning accuracy, and has extremely high movement speed, good maintenance-free operation, long service life, and can ensure no pollution and low noise during conveying.

[0068] In one embodiment, the laser welding mechanism 16 includes a fifth robotic arm 1601, a pressure head adjustment part 1603, a pressure head component 1604, and a second worktable 1606. The fifth robotic arm 1601 has a welding part 1602 at its moving end. The pressure head adjustment part 1603 is arranged around the second worktable 1606. The pressure head component 1604 is installed at the moving end of the pressure head adjustment part 1603. The pressure head adjustment part 1603 is used to drive the pressure head component 1604 to move along its X-axis and Y-axis directions.

[0069] In practice, the module is transferred to the corresponding second worktable 1606 of the laser welding mechanism 16. The pressure head component 1604 moves along its X-axis and Y-axis directions to the top of the second worktable 1606, which is used to position the module. After positioning, the fifth robotic arm 1601 drives the welding part 1602 to move to the second worktable 1606, thereby performing welding processing on the module.

[0070] In one embodiment, the pressure head component 1604 includes a second mounting base 1604a installed at the moving end of the pressure head adjustment part 1603. A downward pressure cylinder 1604b is vertically mounted on the second mounting base 1604a. A servo slide 1604c is installed at the moving end of the downward pressure cylinder 1604b. The servo slide 1604c has multiple moving parts, and each moving part is equipped with a mounting plate 1604d. The servo slide 1604c can drive the mounting plates 1604d on each moving part to move accordingly and change their spacing. A welding pressure head 1604f and a nitrogen protection device are provided on the mounting plate 1604d. A laser rangefinder 1604e is also installed on the servo slide 1604c.

[0071] The nitrogen protection device includes a connection port 1604g installed on the welding head 1604f and communicating with its interior. The welding head 1604f is also provided with an annular guide groove, and the output end of the connection port 1604g is connected to the guide groove.

[0072] In practice, when the pressure head component 1604 moves to the top of the module, the laser ranging unit 1604e can measure the corresponding distance. Then, the downward pressure cylinder 1604b drives each welding pressure head 1604f to descend and press down the module. In addition, the servo slide 1604c drives each moving part to move to the corresponding position. At this time, the mounting plate 1604d and the welding pressure head 1604f on it can also move, thereby changing the relative distance between them. Therefore, better compatibility can be achieved, which can meet the welding needs of more products, reduce the production cost of enterprises, and improve the convenience of changeover.

[0073] In addition, the 1604g connector can guide nitrogen gas into the guide groove and then spray it out evenly in a ring shape, which can protect the module welding process.

[0074] All of the robotic arms mentioned above can be six-axis robots in this field. Since six-axis robots are common knowledge in this field, their specific structural composition and working principle will not be elaborated on in this article.

[0075] It should be noted that if the embodiments of the present invention involve directional indicators (such as up, down, left, right, front, back, etc.), the directional indicators are only used to explain the relative positional relationship and movement of the components in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indicators will also change accordingly.

[0076] Furthermore, if the embodiments of this invention involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. If the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.

[0077] Additionally, "multiple" refers to two or more.

[0078] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A battery module PACK intelligent flexible assembly process, characterized in that, Includes the following steps: S1. Cable replacement and adaptation processing; S101. Product Determination: Pre-determine the type of battery module to be manufactured; S102, Changeover and Adaptation: Based on the product type determined in step S101, when switching production types, the corresponding production formula is called through the software, and the assembly line parameters are adjusted to perform the changeover. After the changeover is completed and qualified, the subsequent production process is started. S2. Battery module production: The following processes are performed sequentially; S201, Cell Processing: The entire tray of cells is transported to the cell processing section by AGV trolley. After scanning and OCV testing, NG cells are sorted out and qualified cells are discharged. After polarity adjustment, qualified cells are glued by the roll glue application mechanism or sheet glue application mechanism. After the glue is removed and the cells pass the manual re-inspection, they are transported to the module stacking section. S202, Module Stacking: After the steel strip is pre-embedded manually, the six-axis robot grabs the battery cell, changes pitch, turns and transports it to the upper and lower alternating stacking platform. After extrusion shaping, end plate / side plate installation and steel strip sleeve, the module code is generated by laser marking and the battery cell data is bound. Then, it is transported to the PACK processing section. S203, PACK processing: The magnetic levitation conveyor line transfers the module to the gluing station to complete the gluing of the liquid cooling plate or the box. After passing the visual inspection, the module is assembled into the box and locked and fixed. The pole is located by visual addressing, and after laser cleaning, the CCS component is installed and the PACK code is bound. The bus is fixed by a servo variable pitch clamping mechanism. After laser welding, the weld is inspected and qualified, and the product is completed and off the production line.

2. A battery module PACK intelligent flexible assembly line, applied to the battery module PACK intelligent flexible assembly process described in claim 1, characterized in that, include: Cell processing section, module stacking section, PACK processing section; The cell processing section includes a cell testing and unpacking module (1), a transfer mechanism (2), a ring conveyor line (3), a roll adhesive application mechanism (4), and a sheet adhesive application mechanism (5), which are used to sequentially perform feeding tests, unqualified sorting, polarity adjustment, adhesive application and peeling detection, and pre-stacking of the cells to complete the cell pre-processing operation. The module stacking section includes a module stacking mechanism (6), a module extrusion mechanism (7), a module marking mechanism (8), a module box entry mechanism (9), a pre-embedded steel strip workstation (10), and a magnetic levitation conveyor line (11), which are used to sequentially perform steel strip pre-embedding, cell stacking and extrusion, end plate and side plate assembly, pressing and measuring distance sleeve steel strip, data binding and uploading, and marking and binding code storage. The PACK processing section includes a liquid cooling plate gluing workstation (12), a module fixing workstation (13), an addressing and cleaning workstation (14), an assembly and binding workstation (15), and a laser welding mechanism (16), which are used to sequentially perform gluing and gluing inspection on the PACK, module placement and locking, cell terminal cleaning, CCS component assembly and binding, bus welding and post-weld inspection, and complete the finished product offline.

3. The intelligent flexible assembly line for battery module PACK according to claim 2, characterized in that: The battery cell testing and disassembly module (1) includes a first robotic arm (101), a battery cell loading assembly (102), and a testing and disassembly assembly (103). The battery cell feeding assembly (102) includes a first mounting base (1021) disposed at the moving end of the first robotic arm (101), a first support (1022) disposed on the first mounting base (1021), a pressure plate cylinder (1023) vertically disposed on the first support (1022), and a plurality of first rotary cylinders (1024) that can slide up and down are also disposed at the bottom of the first support (1022). A compression spring (1025) is also disposed between each first rotary cylinder (1024) and the first support (1022), and an anti-fall gripper (1026) is disposed at the moving end of each first rotary cylinder (1024). The detection and disassembly assembly (103) includes a second support (1031) disposed at the moving end of the first robotic arm (101). A first drive cylinder (1032) is disposed at the bottom of the second support (1031). A plurality of empty disk handling components (1033) are also disposed on the second support (1031). The first drive cylinder (1032) has at least one moving end, and an OCV test probe (1034) is disposed on its moving end. A vision positioning part (1035) is disposed on the second support (1031). A pitch-changing component (1036) is also disposed on the second support (1031). A plate is disposed at the moving end of the pitch-changing component (1036), and at least one first barcode scanner (1037) is disposed on the plate.

4. The intelligent flexible assembly line for battery module PACK according to claim 2, characterized in that: The roll adhesive applicator (4) includes a first worktable (401), an X-axis servo slide (402) is provided on the first worktable (401), a Z-axis servo slide (403) is provided at the moving end of the X-axis servo slide (402), a torque component (404) is provided at the moving end of the Z-axis servo slide (403), an air shaft (405) is provided at the moving end of the torque component (404), a roll of material (406) is provided on the air shaft (405), and a servo drive component (407), at least one guide shaft (408), two rotatably adjustable waste rolls (409), and a strip clamping component (410) are also provided at the moving end of the torque component (404). The sheet adhesive applicator (5) includes a base (501), a hopper component (502) disposed on the base (501), a first drive unit (503), a feeding component (504), a secondary positioning component (505), an adhesive applicator (506), and a release paper peeling component (507). The hopper component (502) has two sets of hopper stations for loading film, and the two sets of hopper stations can alternately supply material to the feeding component (504); The first drive unit (503) is used to drive the feeding unit (504) and the adhesive application unit (506) to move along their X-axis and Y-axis directions; The feeding component (504) is used to grab the film at the hopper station and move it to the secondary positioning component (505); The secondary positioning component (505) is used to perform secondary positioning of the film on it; The release paper tearing component (507) is used to tear the release paper off the film thereon; The adhesive applicator (506) is used to pick up the film from the secondary positioning component (505), send it to the release paper component (507) for processing, and attach the processed film to the battery cell.

5. The intelligent flexible assembly line for battery module PACK according to claim 2, characterized in that: The module stacking mechanism (6) includes a second robotic arm (601), a transfer gripper component (602), a stacking platform component (603), a third robotic arm (604), and a module handling component (605). The transfer gripper component (602) includes a variable pitch slide (6021) disposed at the moving end of the second robotic arm (601). The variable pitch slide (6021) has at least one moving end, and a second rotary cylinder (6022) is disposed at its moving end. A gripper cylinder (6023) is disposed at the moving end of the second rotary cylinder (6022). The stacking platform component (603) includes a platform body (6031) on which at least two stacking portions (6032) are slidably disposed. The stacking section (6032) includes a mounting frame (6032a), on which a centering servo motor (6032b) is mounted. The mounting frame (6032a) also includes a centering timing belt (6032c) and a first linear guide rail (6032d). The mounting frame (6032a) further includes two centering plates (6032e) that can move closer to or further away from each other. The centering servo motor (6032b) can cooperate with the centering timing belt (6032c) and the first linear guide rail (6032d). The guide rail (6032d) drives the two centering plates (6032e) to move closer or further apart. The mounting frame (6032a) is also provided with a second linear guide rail (6032f). The input end of the second linear guide rail (6032f) is provided with a second driving part (6032g). The moving end of the second linear guide rail (6032f) is provided with a clamping push block (6032h). The mounting frame (6032a) is also provided with a fixed reference block (6032i) that cooperates with the clamping push block (6032h). A drive unit (6032k) is provided on the stacking part (6032), and a rack (6032j) is provided on the platform (6031). The drive unit (6032k) includes a servo motor provided on the mounting frame (6032a). A gear is provided on the shaft of the servo motor. The gear meshes with the rack. The drive unit (6032k) can cooperate with the rack (6032j) to drive the stacking part (6032) to move and flow between the picking station of the module handling component (605) and the loading station of the transfer gripper component (602). The module handling component (605) includes a third support (6051) disposed at the moving end of the third robotic arm (604). The third support (6051) is provided with a first clamping screw part (6052). The moving end of the first clamping screw part (6052) is provided with two oppositely distributed first fixed jaws (6053). The bottom of the third support (6051) is provided with a lifting cylinder. The moving end of the lifting cylinder is provided with a first sponge suction cup (6054). The first sponge suction cup (6054) is located at the center of the two first fixed jaws (6053). The third support (6051) is also provided with a bottom support component (6055). The bottom support component (6055) includes a support rod (6055a) rotatably mounted on the side wall of the third support (6051). A connecting frame (6055b) is hinged to the support rod (6055a). An adjusting block (6055c) is hinged to the side of the connecting frame (6055b) away from the support rod (6055a). A second drive cylinder (6055d) is also vertically mounted on the third support (6051). The adjusting block (6055c) is located at the moving end of the second drive cylinder (6055d). The support rod (6055a) is also provided with a detection unit (6055e), which is used to detect the rotation state of the support rod (6055a).

6. The intelligent flexible assembly line for battery module PACK according to claim 2, characterized in that: The module extrusion mechanism (7) includes a first mounting platform (701), a servo electric cylinder (702) is provided on the first mounting platform (701), a fourth support (703) is provided at the moving end of the servo electric cylinder (702), a clamping electric cylinder (704) is provided at the moving end of the fourth support (703), and a clamping plate (705) is provided at the moving end of the clamping electric cylinder (704).

7. The intelligent flexible assembly line for battery module PACK according to claim 2, characterized in that: The module marking mechanism (8) includes a second mounting platform (801), on which an X-axis moving module (802) is provided. A Y-axis moving module (803) is provided at the moving end of the X-axis moving module (802), and a Z-axis moving module (804) is provided at the moving end of the Y-axis moving module (803). A second barcode scanner (805) and a marking galvanometer (806) are provided at the moving end of the Z-axis moving module (804).

8. The intelligent flexible assembly line for battery module PACK according to claim 2, characterized in that: The module loading mechanism (9) includes a fourth robotic arm, a fifth support (901) is provided at the moving end of the fourth robotic arm, a second clamping screw part (902) is provided on the fifth support (901), a second gripper (903) is provided at the moving end of the second clamping screw part (902), and a second sponge suction cup (904) is also provided on the fifth support (901).

9. The intelligent flexible assembly line for battery module PACK according to claim 2, characterized in that: The laser welding mechanism (16) includes a fifth robotic arm (1601), a pressure head adjustment unit (1603), a pressure head component (1604), and a second worktable (1606). The fifth robotic arm (1601) has a welding part (1602) at its moving end. The pressure head adjustment unit (1603) is used to drive the pressure head component (1604) to move along its X-axis and Y-axis directions.

10. The intelligent flexible assembly line for a battery module PACK according to claim 2, characterized in that: The pressure head component (1604) includes a second mounting base (1604a) disposed at the moving end of the pressure head adjustment part (1603). A pressure cylinder (1604b) is disposed on the second mounting base (1604a). A servo slide (1604c) is disposed at the moving end of the pressure cylinder (1604b). The servo slide (1604c) has multiple moving parts, and a mounting plate (1604d) is disposed on each moving part. The servo slide (1604c) can drive the mounting plates (1604d) on each moving part to move accordingly and change their spacing. A welding pressure head (1604f) and a nitrogen protection device are disposed on the mounting plate (1604d). The servo slide (1604c) is also equipped with a laser rangefinder (1604e). The nitrogen protection device includes a connection port (1604g) disposed on and internally communicating with the welding head (1604f). The welding head (1604f) is also provided with an annular guide groove, and the output end of the connection port (1604g) is connected to the guide groove.

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