An automatic clustering device and method for energy storage container PACK

Abstract

This invention relates to the field of new energy storage equipment technology, and in particular to an automatic pACK clustering device and method for energy storage containers. The device includes a pACK rack lifting unit, a pACK transfer unit, a pACK pushing and clustering unit, two sets of ground rail conveying mechanisms, and a central control system. The pACK rack lifting unit lifts the rack frame separately from the pACK; the pACK transfer unit retrieves the pACK from the picking position and transports it to the pACK pushing and clustering unit; the pACK pushing and clustering unit transfers the pACK to the target position inside the container; the two sets of ground rail conveying mechanisms respectively support the horizontal reciprocating movement of the pACK transfer unit and the pACK pushing and clustering unit; the central control system controls each unit to coordinate its actions according to a preset rhythm. This invention achieves fully automatic pACK clustering, effectively reducing transport space, improving clustering efficiency and accuracy, meeting the automatic clustering requirements of heavy-duty pACKs, and solving the technical problems of existing automatic pACK clustering methods, such as large footprint, slow cycle time, and high maintenance costs.

Description

Technical Field

[0001] This invention relates to the field of new energy storage equipment technology, and in particular to an automatic clustering device and method for energy storage container PACKs. Background Technology

[0002] The field of automated pACK clustering equipment for energy storage containers is rapidly developing from relying on manual labor and imported equipment to independently developing intelligent equipment. Breakthroughs are being made in core technologies such as load capacity and precision control, while the field is also constantly upgrading towards flexibility and digitalization.

[0003] Packet clustering is a crucial step in the assembly of energy storage containers, directly impacting the quality and performance of the entire energy storage system. Traditional energy storage battery pack integration production lines primarily rely on forklift-driven operations combined with manual handling, resulting in low production efficiency and numerous safety hazards. To address the shortcomings of manual methods, semi-automated clustering equipment has emerged in the industry. While this reduces some manual operation, it still requires operators to guide the process through cameras and displays, failing to achieve fully unmanned operation.

[0004] While existing AGV-based fully automated clustering equipment achieves automation, the AGVs themselves require significant operating space and turning radius, placing high demands on production line layout. Similarly, gantry robots and heavy-duty industrial robots require substantial installation space and operating areas, making compact layouts difficult to achieve within limited production workshops. Current clustering methods suffer from slow cycle times, failing to meet the efficiency requirements of large-scale mass production. They also exhibit high equipment maintenance costs and limited adaptability to different pack sizes. Furthermore, they demonstrate significant deficiencies in structural strength and operational stability when handling heavy-duty packs weighing 1300 kg or more.

[0005] In summary, existing energy storage container PACK clustering technology has significant shortcomings in terms of automation level, operation efficiency, space utilization, and heavy load capacity. There is an urgent need for an automated PACK clustering device and method that can achieve full automation, high cycle time, good heavy load performance, and compact layout. Summary of the Invention

[0006] To address the shortcomings of existing technologies, this invention provides an automatic clustering device and method for energy storage container PACKs, which realizes fully automated operation from PACK receiving from the rack to clustering, effectively reducing the conveying space, improving clustering efficiency, accuracy and safety, and meeting the automated clustering requirements of heavy-duty PACKs. It solves the technical problems of existing automatic PACK clustering methods, such as large footprint, slow cycle time and high maintenance cost.

[0007] To achieve the above-mentioned technical objectives, the present invention adopts the following technical solution: In a first aspect, the present invention provides an automatic clustering device for an energy storage container PACK, comprising an electrical box rack lifting unit, an electrical box transfer unit, a material pushing and clustering unit, two sets of ground rail conveying mechanisms, and a central control system; The electrical box rack lifting unit is used to receive multi-layer racks carrying PACKs and to lift the rack frame separately from the PACKs. The electrical box transfer unit is used to obtain the PACK from the material picking position of the electrical box material rack lifting unit and transport the qualified PACK to the material pushing and clustering unit; The pusher unit is used to receive the PACK delivered by the electrical box transfer unit and transfer the PACK to the target location inside the energy storage container. The two sets of ground rail conveying mechanisms are configured to carry the electrical box transfer unit and the material pushing and feeding unit respectively, and move horizontally back and forth along their respective ground rails to adjust the working position; The central control system is connected to the electrical box rack lifting unit, electrical box transfer unit, material pushing and clustering unit, and two sets of ground rail conveying mechanisms. It controls each unit mechanism to coordinate its actions according to a preset rhythm to complete the fully automatic operation of the PACK from material receiving from the rack to entering the cluster.

[0008] In some possible implementations, the electrical box rack lifting unit includes a positioning mechanism and two lifting mechanisms located on both sides of the rack and working in sync. The positioning mechanism is used to guide the rack loaded with PACK into the working position and to position the rack. The lifting mechanism includes a lifting frame and a lifting drive mechanism, a lower lifting component, an upper lifting component, a lateral movement drive mechanism, and a first jacking mechanism connected to the lifting frame; The lifting drive mechanism is configured to drive the lower lifting component to rise and fall vertically while simultaneously moving the upper lifting component synchronously. The lower and upper lifting components are each connected to a set of material-carrying trays on the side near the material rack. The transverse drive mechanism is configured with two sets and drives the two sets of material-carrying trays to move independently in the horizontal direction, so as to abut against and support the PACK or material rack frame located at different height layers. The first lifting mechanism is used to drive the upper lifting component to move vertically relative to the lower lifting component, so as to adjust the distance between the upper and lower sets of material carrying trays, realize the staggered separation of the material rack frame and PACK located on the upper and lower layers, and leave space for the electrical box transfer unit to pick up materials.

[0009] In some possible implementations, the electrical box rack lifting unit further includes a plurality of folding leg mechanisms disposed around the rack. The folding leg mechanism includes a folding leg frame, a lifting mechanism vertically disposed on the folding leg frame, a transverse movement mechanism connected to the lifting mechanism, and a clamping mechanism and a rotating mechanism disposed on the transverse movement mechanism. The clamping mechanism is used to clamp the legs of the single-layer material rack frame; the lifting mechanism is used to drive the lateral movement mechanism to move the clamping mechanism back and forth in the vertical direction; the lateral movement mechanism is used to drive the clamping mechanism to move back and forth in the horizontal direction; the rotating mechanism converts the linear driving force into rotational motion to drive the legs of the material rack frame clamped by the clamping mechanism to rotate and fold.

[0010] Each folding leg mechanism is connected to the central control system. The central control system sends control signals to each folding leg mechanism synchronously, so that each folding leg mechanism clamps the corresponding material rack frame support leg at the same time and rotates and folds synchronously. This is used to quickly lower the upper material rack support leg when the lower battery pack is retrieved, so as to avoid collision with the surrounding equipment during the lifting of the upper material rack frame, and to leave enough lifting space when the lifting mechanism lifts the PACK or material rack frame separately.

[0011] In some possible implementations, the electrical box transfer unit includes a height adjustment mechanism, a lifting frame connected to the height adjustment mechanism, a fork arm mechanism disposed on the lifting frame, and two sets of plate chain transfer mechanisms disposed on the outer side of the fork arm mechanism. The bottom of the height adjustment mechanism is connected to the ground rail conveying mechanism, which is used to drive the lifting frame to move vertically. The fork arm mechanism includes a fork arm drive unit connected to the lifting frame and at least two sets of fork arms connected to the fork arm drive unit. The plate chain transfer mechanism includes a plate chain bracket fixed on the lifting frame, a plate chain drive component 1 disposed on the plate chain bracket, and a transfer plate chain driven by the plate chain drive component 1 and rotating around the plate chain bracket. The transfer plate chain is aligned with the length direction of the fork arm.

[0012] During operation, the electrical box transfer unit is driven to move horizontally to the corresponding position on the material rack via the ground rail conveyor mechanism; the lifting frame is driven to move vertically to the height corresponding to the PACK to be picked up via the height adjustment mechanism; the fork arm is driven to move horizontally via the fork arm drive component, and the PACK is picked up with the fork extension, and then the fork arm retracts to transfer the PACK to the top of the plate chain transfer mechanism; the plate chain drive component drives the transfer plate chain to rotate, which drives the PACK supported on the transfer plate chain to move backward for transfer to external devices.

[0013] In some possible implementations, the plate chain transfer mechanism is further provided with a second lifting mechanism. The second lifting mechanism includes a push-pull cylinder fixed on the lifting frame and two wedge blocks that are horizontally slidably connected to the lifting frame. The two wedge blocks are connected by a connecting rod and move in the same direction. One of the wedge blocks is connected to the floating joint of the push-pull cylinder to achieve synchronous linkage. The plate chain bracket is connected to a roller support, and at least two sets of rollers are connected below the roller support. The wedge surface above each wedge block abuts against at least one roller. A guide rail seat is also vertically installed on the lifting frame. The roller support and the guide rail seat are vertically slidably connected by a linear module.

[0014] After the fork arm mechanism transfers the PACK to the top of the transfer chain, the push-pull cylinder drives the wedge block to reciprocate in the horizontal direction. The roller rolls on the wedge surface of the wedge block, converting the horizontal motion into the vertical lifting motion of the chain transfer mechanism, thereby lifting the transfer chain from below to meet the PACK, achieving a smooth transition of the PACK from the fork arm to the transfer chain.

[0015] In some possible implementations, an NG diversion unit is provided downstream of the electrical box transfer unit. The NG diversion unit includes an NG material rack and two sets of guide rollers slidably connected to the top of the NG material rack. Two sets of hand crank screws are provided at the top of the NG material rack, and the two sets of guide rollers are respectively connected to one set of hand crank screws by thread engagement. The electrical box transfer unit is equipped with a code reading mechanism that communicates with the central control system. This mechanism reads the identification code of the PACK after it is acquired by the electrical box transfer unit. PACKs with invalid codes are transferred by the electrical box transfer unit to the guide roller conveyor of the NG (Not Required) rack for NG diversion. During NG diversion, the electrical box transfer unit adjusts the height of the fork arm to match the height of the upper surface of the guide roller conveyor via a height adjustment mechanism. The movement direction of the PACK on the guide roller conveyor is consistent with the extension and retraction direction of the fork arm. Furthermore, the distance between the two sets of guide roller conveyors can be adjusted by hand-cranking a screw to accommodate PACKs of different sizes. The NG rack in this invention is a movable trolley mechanism. An NG positioning frame is set at the NG diversion position to position the movable NG rack.

[0016] In some possible implementations, the feeding unit includes a feeding lifting mechanism, a feeding transverse mechanism, and a feeding plate chain mechanism, wherein the bottom of the feeding lifting mechanism is connected to the ground rail conveying mechanism. The clustering lateral movement mechanism includes a lifting frame, a sliding frame slidably connected to the upper part of the lifting frame, and a lateral movement frame located below the lifting frame. A hanger is movably installed in the middle of the lifting frame. The sliding frame and the lateral movement frame are fixedly connected by the hanger. A horizontal lateral movement rack is provided on the lifting frame, and a lateral movement drive assembly that meshes with the lateral movement rack is provided on the sliding frame. The lateral drive assembly drives the slide frame to move relative to the lifting frame by means of lateral rack and pinion meshing transmission; The cluster entry lifting mechanism is connected to the lifting frame and is used to drive the lifting frame to move back and forth in the vertical direction; The clustering plate chain mechanism includes a plate chain mounting base and a clustering plate chain mounted on a transverse frame. Both ends of the plate chain mounting base are provided with a plate chain drive component and two sets of sprockets that mesh with the clustering plate chain. The output end of the plate chain drive component drives the clustering plate chain to rotate through the connecting sprockets, thereby transporting the PACK supported by the clustering plate chain to the energy storage container.

[0017] In some possible implementations, a set of pushing mechanisms is provided on the opposite outer side of the clustering plate chain mechanism. The pushing mechanism includes a second adjusting motor fixed on the transverse frame, a second adjusting screw connected to the output end of the second adjusting motor, and a pushing frame connected to the second adjusting screw. One end of the pusher frame is fixed with a pusher motor, the output end of the pusher motor is connected to a pusher screw, a connecting block is threaded onto the pusher screw, the connecting block is slidably connected to the pusher frame, and a vertically sliding slide cylinder is installed on the connecting block, with a horizontal pusher head connected to the slide cylinder.

[0018] When the clustering plate chain mechanism docks with the electrical box transfer unit, the PACK is transferred to the top of the clustering plate chain. Then, the container entry position of the PACK is adjusted vertically and horizontally by the clustering lifting mechanism and the ground rail conveying mechanism. Next, when the container is clustered, the clustering plate chain drives the PACK to move backward. At the same time, the second pitch motor drives the second pitch screw to move the pusher frame from both sides to approach the PACK. The slide cylinder adjusts the height of the pusher head to correspond with the PACK. The pusher motor drives the pusher head to move along the pusher screw, thereby abutting and pushing the PACK to move backward into the cluster.

[0019] In some possible implementations, a door opening mechanism is also included for automatically opening the container doors; The door opening mechanism includes a support frame located around the energy storage container, a suspension beam located above the support frame, and at least one set of automatic door opening components located on the suspension beam; The automatic door opening assembly includes a base slidably connected to the suspension beam, a moving motor and a primary rotary motor fixed on the base, a mounting bracket connected to the output end of the primary rotary motor, a sliding frame slidably connected below the mounting bracket, a secondary rotary motor fixedly connected to the sliding frame, a rotating link rotatably connected to the sliding frame, and a door suction assembly connected to the bottom end of the rotating link. The moving motor moves horizontally along the length of the suspension beam through a gear and rack mechanism, and the secondary rotary motor drives the rotating link to rotate through belt transmission. The door suction assembly includes a suction cup cylinder fixed to the bottom end of the rotating linkage, a door suction bracket slidably connected to the bottom end of the rotating linkage, and a sponge suction cup fixed to the side of the door suction bracket. The sponge suction cup can prevent damage to the container door while fixing it.

[0020] The energy storage container is carried into the station by an AGV / RGV, positioned by a trolley positioning mechanism, and its door is automatically opened by an opening mechanism for the pack to be clustered. During operation, the opening mechanism works as follows: a moving motor drives the base to slide along the suspension beam via a rack and pinion mechanism, roughly positioning the entire opening assembly directly above the container door lock bar; a primary rotary motor drives the mounting frame to rotate, causing the opening mechanism below to swing to the appropriate operating angle; simultaneously, the suction cup cylinder extends, pushing the door suction bracket to slide, causing the sponge suction cups to adhere tightly to the container door panel surface under negative pressure; then, a secondary rotary motor drives the rotating linkage to rotate around its own axis via belt drive, while the primary rotary motor rotates in the opposite direction, thus causing the suction-bearing door to rotate around the door hinge via the mounting frame and sponge suction cups, automatically opening the door.

[0021] Secondly, the present invention provides an automatic clustering method for an energy storage container PACK based on the above-mentioned automatic clustering device, comprising the following steps: S1, Material rack receiving and separation lifting: The material rack carrying at least one PACK is received by the electrical box material rack lifting unit, and the material rack frame is lifted separately from the PACK so that the PACK is at the material picking height; S2, PACK material retrieval: The electrical box transfer unit is driven horizontally by the ground rail conveyor mechanism to the material picking position of the electrical box material rack lifting unit, and the electrical box transfer unit obtains the lifted PACK. S3, PACK forwarding: The ground rail conveyor drives the transfer unit carrying the electrical box to move horizontally to the feeding and clustering unit, and transports the acquired PACK to the feeding and clustering unit. S4, Cluster entry position adjustment and material pushing: Another set of ground rail conveying mechanisms drives the feeding and clustering unit to move horizontally to the clustering port of the energy storage container, and the feeding and clustering unit transfers the received PACK to the target position inside the energy storage container. S5, Cooperative beat control: The central control system controls the electrical box material rack lifting unit, electrical box transfer unit, material pushing and clustering unit, and two sets of ground rail conveying mechanisms to work together according to the preset rhythm, and executes steps S1 to S4 in a loop until all PACKs are automatically clustered.

[0022] The beneficial effects of this invention are as follows: (1) Achieve fully automated operation and greatly improve clustering efficiency: Through the coordinated operation of the electrical box material rack lifting unit, electrical box transfer unit, material pushing and clustering unit, two sets of ground rail conveying mechanisms and the central control system, the present invention can automatically complete all processes of receiving PACK from the material rack and entering the cluster, without the need for manual intervention.

[0023] (2) Separate lifting and leg folding design to ensure safe and smooth material handling: The electrical box material rack lifting unit of the present invention can separate the material rack frame from the PACK in a staggered manner, providing sufficient material handling space for the electrical box transfer unit, avoiding collision interference, and improving the safety and reliability of material handling.

[0024] (3) Stable transfer and accurate clustering, with good heavy-duty performance: The clustering device of the present invention can meet the fully automatic feeding of 1300KG products in the market and has good heavy-duty performance; the electrical box transfer unit realizes the smooth acceptance of PACK and avoids damage; the pusher clustering unit has vertical and horizontal multi-degree-of-freedom position adjustment function, which can accurately align the target position in the container and is compatible with different specifications of PACK, ensuring clustering quality and versatility.

[0025] (4) The overall control system coordinates the rhythm control to optimize the overall operation rhythm.

[0026] This invention uses a central control system to control the coordinated actions of each unit according to a preset rhythm, enabling multi-station parallel operation. This ensures that each process is closely connected and the rhythm is optimal, thereby maximizing clustering efficiency while ensuring accuracy and meeting the needs of large-scale production. Attached Figure Description

[0027] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used together with the embodiments of the invention to explain the invention and do not constitute a limitation thereof.

[0028] Figure 1 This is a three-dimensional structural schematic diagram of the automatic clustering device for the energy storage container PACK of the present invention; Figure 2 This is a three-dimensional structural diagram of the electrical box material rack lifting unit and the material rack in this invention; Figure 3 This is a side view of the positioning mechanism, lifting mechanism, and material rack in this invention. Figure 4 This is a three-dimensional structural diagram of the lifting mechanism in this invention; Figure 5 This is another three-dimensional structural diagram of the lifting mechanism in this invention; Figure 6 This is a three-dimensional structural diagram of the positioning mechanism in this invention; Figure 7 This is a three-dimensional structural diagram of the folding leg mechanism in this invention; Figure 8 This is a three-dimensional structural diagram of the transverse and rotary mechanisms in this invention; Figure 9 This is a three-dimensional structural diagram of the clamping mechanism and the rotating mechanism in this invention; Figure 10This is a three-dimensional structural diagram of the electrical box transfer unit and the ground rail conveying mechanism in this invention; Figure 11 This is a three-dimensional structural diagram of the height adjustment mechanism in this invention; Figure 12 This is a schematic diagram showing the connection relationship between the lifting frame, the fork arm mechanism, and the plate chain transfer mechanism in this invention; Figure 13 This is a three-dimensional structural diagram of the fork arm mechanism in this invention; Figure 14 This is a schematic diagram showing the connection relationship between the lifting frame, the plate chain transfer mechanism, and the second lifting mechanism in this invention; Figure 15 This is a schematic diagram showing the connection relationship between the plate chain transfer mechanism and the second lifting mechanism in this invention; Figure 16 This is a three-dimensional structural diagram of the NG shunt unit in this invention; Figure 17 This is a three-dimensional structural diagram of the feeding cluster unit in this invention; Figure 18 This is a three-dimensional structural schematic diagram of the cluster lifting mechanism in this invention; Figure 19 This is a schematic diagram of the structure of the clustering transverse movement mechanism, the clustering plate chain mechanism, and the pushing mechanism in this invention; Figure 20 This is a three-dimensional structural schematic diagram of the cluster transverse movement mechanism in this invention; Figure 21 This is a schematic diagram showing the connection relationship between the clustering plate chain mechanism, the pushing mechanism, and the transverse shift frame in this invention; Figure 22 This is a three-dimensional structural schematic diagram of the clustering plate chain mechanism in this invention; Figure 23 This is a three-dimensional structural diagram of the feeding mechanism in this invention; Figure 24 This is a schematic diagram showing the positional relationship between the door opening mechanism and the energy storage container in this invention; Figure 25 This is a three-dimensional structural diagram of the automatic door opening component in this invention.

[0029] Explanation of markings in the diagram: 1. Electrical box material rack lifting unit; 11. Positioning mechanism; 111. Bearing plate; 112. Side pushing mechanism; 113. Guiding mechanism; 12. Lifting mechanism; 121. Lifting frame; 122. Lifting drive mechanism; 1221. Servo motor; 1222. Vertical lead screw assembly; 1223. Lead screw nut seat; 123. Lower lifting component; 124. Upper lifting component; 125. Horizontal movement drive mechanism; 126. First lifting mechanism; 1261. Lifting cylinder; 1262. Lifting plate; 127. Material support plate; 13. Leg-folding mechanism; 131. Leg-folding frame; 132. Lifting mechanism; 133. Lateral movement mechanism; 1331. Base plate; 1332. Lateral movement motor; 1333. Rack plate; 1334. Lateral movement slide rail; 1335. Lateral movement plate; 134. Clamping mechanism; 135. Rotation mechanism; 1351. Linear drive component; 1352. Tie rod component; 1353. U-shaped joint; 1354. Bearing seat; 1355. Rotating shaft; 2. Electrical box transfer unit; 21. Height adjustment mechanism; 211. Vertical frame 1; 212. Lifting motor 1; 213. Screw drive component; 214. Vertical guide rail; 215. Slider seat; 22. Improve the framework; 23. Fork arm mechanism; 231. Fork arm drive component; 2311. Drive motor; 2312. Drive shaft; 232. Fork arm; 24. Plate chain transfer mechanism; 241. Plate chain support; 242. Plate chain drive component 1; 243. Transfer plate chain; 244. Sprocket 1; 245. Guide wheel; 25. Second lifting mechanism; 251. Push-pull cylinder; 252. Wedge block; 253. Connecting rod; 254. Roller support; 255. Roller; 256. Guide rail seat; 3. Material feeding unit; 31. Cluster entry lifting mechanism; 311. Vertical frame II; 312. Lifting motor II; 313. Steering and reduction mechanism; 314. Lifting screw; 32. Cluster entry lateral movement mechanism; 321. Lifting frame; 322. Slide frame; 323. Lateral movement frame; 324. Hanger; 325. Lateral movement rack; 326. Lateral movement drive assembly; 327. Adjustable pitch motor one; 328. Adjustable pitch lead screw one; 329. Cylinder locking mechanism; 33. Clustering plate chain mechanism; 331. Plate chain mounting base; 332. Clustering plate chain; 333. Plate chain drive component two; 334. Sprocket two; 34. Pushing mechanism; 341. Adjustable pitch motor II; 342. Adjustable pitch lead screw II; 343. Pushing frame; 344. Pushing motor; 345. Pushing lead screw; 346. Connecting block; 347. Slide table cylinder; 348. Pushing head; 4. Ground rail conveying mechanism; 41. Ground rail; 42. Ground rail support plate; 43. Ground rail motor; 44. Rail rack; 5. NG diversion unit; 51. NG material rack; 52. Guide roller conveyor; 53. Hand crank screw; 54. NG positioning frame; 6. Code reading institutions; 7. Door opening mechanism; 71. Support frame; 72. Suspension beam; 73. Automatic door opening assembly; 731. Base; 732. Moving motor; 733. Primary rotary motor; 734. Mounting bracket; 735. Sliding bracket; 736. Secondary rotary motor; 737. Rotating linkage; 738. Door suction assembly; 7381. Suction cup cylinder; 7382. Door suction bracket; 7383. Sponge suction cup; 739. Gear and rack mechanism; 8. Car positioning mechanism; 100, PACK; 200, Material rack; 300, Energy storage container; 301, Container door. Detailed Implementation

[0030] The following specific embodiments illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. Although the description of the present invention will be presented in conjunction with preferred embodiments, this does not mean that the features of the invention are limited to these embodiments.

[0031] In the description of this embodiment, it should be noted that the terms "upper," "lower," "left," "right," "inner," "outer," "top," "bottom," "front," and "rear," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product is in use. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to has a specific orientation, or is constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the present invention. The terms "first," "second," etc., are only used to distinguish descriptions and should not be construed as indicating or implying relative importance. Unless otherwise expressly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal connection of two components. For those skilled in the art, the specific meaning of the above terms in this embodiment can be understood according to the specific circumstances.

[0032] To make the objectives, technical solutions, and advantages of the present invention clearer, the embodiments of the present invention will be described in further detail below with reference to the accompanying drawings.

[0033] refer to Figure 1One embodiment of the present invention provides an automatic clustering device for energy storage container PACK, including an electrical box material rack lifting unit 1, an electrical box transfer unit 2, a material pushing and clustering unit 3, two sets of ground rail conveying mechanisms 4, and a central control system (not shown in the figure).

[0034] The electrical box rack lifting unit 1 is used to receive the rack 200 carrying at least one PACK100. After positioning the rack, it separates the rack frame from the PACK100 and lifts it to provide sufficient space for the electrical box transfer unit 2 to pick up electrical boxes.

[0035] The electrical box transfer unit 2 is located downstream of the electrical box rack lifting unit 1. It is used to obtain PACK100 from the material picking position of the electrical box rack lifting unit 1 and transport qualified PACK100 to the push-in cluster unit 3.

[0036] The feeding unit 3 is located downstream of the electrical box transfer unit 2. It is used to receive the PACK100 conveyed by the electrical box transfer unit 2 and transfer the PACK100 to the target position inside the energy storage container 300.

[0037] The two sets of ground rail conveying mechanisms 4 are configured to carry the electrical box transfer unit 2 and the material pushing and clustering unit 3 respectively, and move horizontally back and forth along their respective ground rails to adjust the working position.

[0038] The central control system communicates with the electrical box material rack lifting unit 1, electrical box transfer unit 2, material pushing into cluster unit 3, and two sets of ground rail conveying mechanisms 4, and controls each unit mechanism to coordinate its actions according to a preset rhythm to complete the fully automatic operation of PACK100 from material receiving from the rack to entering the cluster.

[0039] refer to Figures 2 to 6 Based on the above embodiments, the specific structure of the electrical box rack lifting unit 1 will be described in detail. The electrical box rack lifting unit 1 includes a positioning mechanism 11 and two lifting mechanisms 12 located on both sides of the rack 200 and cooperating synchronously.

[0040] The positioning mechanism 11 is used to guide the rack 200 loaded with PACK 100 into the working position and to position the rack 200. Specifically, refer to Figure 6 The positioning mechanism 11 includes side positioning units and end positioning units symmetrically arranged on both sides of the material rack. The side positioning unit includes a support plate 111, a side pushing mechanism 112, and a guide mechanism 113. The support plate 111 is used to support the material rack, the side pushing mechanism 112 is used to clamp and position the material rack from both sides, and the guide mechanism 113 is used to drive the support plate 111 to move the material rack in the horizontal direction into the preset working position, and to limit the end position through the end positioning unit at the end of the material rack in the conveying direction.

[0041] refer to Figures 3 to 5The lifting mechanism 12 includes a lifting frame 121 and a lifting drive mechanism 122, a lower lifting component 123, an upper lifting component 124, a transverse drive mechanism 125, and a first lifting mechanism 126 connected to the lifting frame 121.

[0042] The lifting drive mechanism 122 is configured to drive the lower lifting member 123 to move vertically while simultaneously moving the upper lifting member 124 synchronously. Specifically, refer to... Figure 3 and Figure 4 The lifting drive mechanism 122 includes a servo motor 1221 fixed to the top of the lifting frame 121, and a vertical lead screw assembly 1222 coaxially connected to the output shaft of the servo motor 1221. The vertical lead screw assembly 1222 is connected to the lower lifting member 123 via a lead screw nut seat 1223, and the lower lifting member 123 and the upper lifting member 124 are connected via a first lifting mechanism 126. The servo motor 1221 drives the lower lifting member 123 to move vertically up and down via the vertical lead screw assembly 1222, while simultaneously driving the upper lifting member 124 to move synchronously.

[0043] refer to Figure 4 A set of material-carrying trays 127 are connected to the side of the lower lifting member 123 and the upper lifting member 124 near the material rack, respectively. The transverse drive mechanism 125 is equipped with two sets and drives the two sets of material-carrying trays 127 to move independently in the horizontal direction, so as to abut and support the PACK100 or material rack frame located at different height layers.

[0044] The first lifting mechanism 126 is used to drive the upper lifting member 124 to move vertically relative to the lower lifting member 123, so as to adjust the distance between the upper lifting member 124 and the lower lifting member 123, that is, the distance between the upper and lower sets of material carrying trays 127, thereby realizing the staggered separation of the material rack frame located on the upper and lower layers from the PACK 100, leaving space for the material picking up of the electrical box transfer unit 2. Specifically, refer to Figure 4 and Figure 5 The first lifting mechanism 126 includes a lifting cylinder 1261 vertically mounted above the lower lifting member 123 and a lifting plate 1262 connected to the piston rod end of the lifting cylinder 1261. The lifting plate 1262 is fixedly connected to the upper lifting member 124. When the piston rod of the lifting cylinder 1261 extends, the lifting plate 1262 pushes the upper lifting member 124 to rise independently relative to the lower lifting member 123, thereby driving the material carrier plate 127 connected to the upper lifting member 124 to separate the upper PACK 100 or material rack frame it supports from the lower material rack frame or PACK 100.

[0045] refer to Figure 2 and Figure 7Based on the above embodiments, the electrical box rack lifting unit 1 also includes multiple folding leg mechanisms 13 disposed around the rack, typically four folding leg mechanisms are disposed around the four legs of the rack frame.

[0046] refer to Figures 7 to 9 The leg-folding mechanism 13 includes a leg-folding frame 131, a lifting mechanism 132 vertically mounted on the leg-folding frame 131, a transverse mechanism 133 connected to the lifting mechanism 132, and a clamping mechanism 134 and a rotating mechanism 135 mounted on the transverse mechanism 133. The clamping mechanism 134 is used to clamp the legs of the single-layer material rack frame. The lifting mechanism 132 is used to drive the transverse mechanism 133 to move the clamping mechanism 134 reciprocally in the vertical direction. The transverse mechanism 133 is used to drive the clamping mechanism 134 to move reciprocally in the horizontal direction. The rotating mechanism 135 converts the linear driving force into rotational motion to drive the legs of the material rack frame clamped by the clamping mechanism 134 to rotate and fold.

[0047] Specifically, the transverse mechanism 133 includes a base plate 1331 connected to the lifting mechanism 132, a transverse motor 1332 fixed on the base plate 1331, a rack plate 1333 meshing with the output end of the transverse motor 1332, a transverse slide rail 1334 fixedly connected to the rack plate 1333, and a transverse plate 1335 slidably connected to the transverse slide rail 1334.

[0048] The rotating mechanism 135 includes a linear drive 1351 fixed on a transverse plate 1335, a pull rod 1352 connected to the output end of the linear drive 1351, a U-shaped connector 1353 movably connected to the pull rod 1352, a bearing seat 1354 connected to the transverse plate 1335, and a rotating shaft 1355 rotatably connected to the bearing seat 1354. The U-shaped connector 1353 has an elongated slot, through which the end of the pull rod 1352 movably passes. One side of the rotating shaft 1355 is connected to the U-shaped connector 1353, and the other side is connected to a clamping mechanism 134. The clamping mechanism 134 includes two opposing gripper plates, with an elastic rod connecting the gripper plates to the gripper seat plate to achieve flexible clamping of the material rack legs. The linear drive 1351 converts linear motion into rotational motion through the tie rod 1352, the U-shaped joint 1353 and the rotating shaft 1355, thereby driving the support legs of the material rack frame held by the clamping mechanism 134 to rotate and fold.

[0049] Each folding leg mechanism 13 is communicatively connected to the central control system. The central control system synchronously sends control signals to each folding leg mechanism 13, so that each folding leg mechanism 13 clamps the corresponding material rack frame support leg at the same time and rotates and folds synchronously. This is used to quickly lower the upper material rack support leg when the lower battery pack is taken out, so as to avoid collision with the surrounding equipment during the lifting of the upper material rack frame, and to leave enough lifting space for the lifting mechanism 12 to lift the PACK100 or the material rack frame separately.

[0050] refer to Figures 10 to 15 Based on the above embodiments, the specific structure of the electrical box rack lifting unit 1 will be described in detail. The electrical box transfer unit 2 includes a height adjustment mechanism 21, a lifting frame 22 connected to the height adjustment mechanism 21, a fork arm mechanism 23 disposed on the lifting frame 22, and two sets of plate chain transfer mechanisms 24 disposed on the outer side of the fork arm mechanism 23.

[0051] The bottom of the height adjustment mechanism 21 is connected to the ground rail conveying mechanism 4, and is used to drive the lifting frame 22 to move vertically. Specifically, refer to... Figure 11 The height adjustment mechanism 21 includes a vertical frame 211, a lifting motor 212, and a screw drive 213. The lifting motor 212 is fixed to the top of the vertical frame 211, and the screw drive 213 is vertically installed in the vertical frame 211 and connected to the lifting frame 22. The vertical frame 211 is provided with multiple sets of vertical guide rails 214, and the side of the lifting frame 22 is provided with multiple sets of slider seats 215, which are slidably connected to the vertical guide rails 214 through the slider seats 215.

[0052] refer to Figure 12 and Figure 13 The fork arm mechanism 23 includes a fork arm drive unit 231 connected to the lifting frame 22 and at least two sets of fork arms 232 connected to the fork arm drive unit 231. Specifically, the fork arm drive unit 231 includes a drive motor 2311 and a transmission shaft 2312 connected to the output end of the drive motor 2311. The two ends of the transmission shaft 2312 are rotatably connected to the lifting frame 22. The fork arms 232 are perpendicularly distributed to the transmission shaft 2312, and the two are connected and synchronously linked by transmission components such as gears, racks, belts, and sprockets. The drive motor 2311 drives the transmission shaft 2312 to rotate, and further drives the fork arms 232 carrying PACK100 to move back and forth in the horizontal direction.

[0053] refer to Figure 12 , Figure 14 and Figure 15 The plate chain transfer mechanism 24 includes a plate chain support 241 fixed to the lifting frame 22, a plate chain drive component 242 mounted on the plate chain support 241, and a transfer plate chain 243 driven by the plate chain drive component 242 and rotating around the plate chain support 241. The plate chain drive component 242 may be a servo motor, and the transfer plate chain 243 is aligned with the length direction of the fork arm 232. At each end of its length direction, the plate chain support 241 is equipped with a set of sprockets 244 that mesh with the transfer plate chain 243. One set of sprockets 244 is connected to the output end of the plate chain drive component 242 and rotates synchronously. Several sets of guide wheels 245 are mounted along the length direction of the plate chain support 241, and the guide wheels 245 are located above the sprockets 244.

[0054] refer to Figure 14 and Figure 15 The plate chain transfer mechanism 24 is also equipped with a second lifting mechanism 25. The second lifting mechanism 25 includes a push-pull cylinder 251 fixed on the lifting frame 22 and two wedge blocks 252 that are horizontally slidably connected to the lifting frame 22. The two wedge blocks 252 are connected by a connecting rod 253 and move in the same direction. One of the wedge blocks 252 is connected to the floating joint of the push-pull cylinder 251 to achieve synchronous linkage. A roller support 254 is connected to the plate chain bracket 241. At least two sets of rollers 255 are connected below the roller support 254. The wedge surface above each wedge block 252 abuts against at least one roller 255. A guide rail seat 256 is also vertically installed on the lifting frame 22. The roller support 254 and the guide rail seat 256 are vertically slidably connected by a linear module.

[0055] During operation, the electrical box transfer unit 2 is driven horizontally to the corresponding position on the material rack 200 by the ground rail conveyor mechanism 4. The lifting frame 22 is driven by the height adjustment mechanism 21 to move the fork arm 232 vertically to the height corresponding to the PACK 100 being picked up. The fork arm drive component 231 drives the fork arm 232 to move horizontally, using the extended fork to pick up the PACK 100, and then the fork arm 232 retracts to transfer the PACK 100 to the top of the plate chain transfer mechanism 24. After the fork arm mechanism 23 transfers the PACK to the top of the transfer plate chain 243, the push-pull cylinder 251 drives the wedge block 252 to reciprocate horizontally, and the roller 255 rolls on the wedge surface of the wedge block 252, converting the horizontal movement into the vertical lifting and lowering movement of the plate chain transfer mechanism 24, thereby lifting the transfer plate chain 243 from below to meet the PACK, realizing a smooth transition of the PACK from the fork arm 232 to the transfer plate chain 243. Finally, the transfer plate chain 243 is driven to rotate by the plate chain drive component 242, which drives the PACK supported on the transfer plate chain 243 to move backward and transfer it to the push-in cluster unit 3.

[0056] refer to Figures 1 to 16 Based on the above embodiments, an NG diversion unit 5 is provided downstream of the electrical box transfer unit 2. The NG diversion unit 5 includes an NG material rack 51 and two sets of guide roller conveyors 52 that are slidably connected to the top of the NG material rack 51 via a linear module. Two sets of hand-cranked screws 53 are provided at the top of the NG material rack 51, and the two sets of guide roller conveyors 52 are respectively connected to one set of hand-cranked screws 53 by thread engagement.

[0057] The electrical box transfer unit 2 is equipped with a code reading mechanism 6 that communicates with the central control system. It is used to read the identity code after the electrical box transfer unit 2 obtains PACK100. PACK100 that fails the code reading is transferred through the electrical box transfer unit 2 to the guide roller 52 of the NG material rack 51 for NG diversion.

[0058] During NG diversion, the electrical box transfer unit 2 adjusts the height of the fork arm 232 to match the height of the upper surface of the guide roller conveyor 52 via the height adjustment mechanism 21. The movement direction of the PACK100 on the guide roller conveyor 52 is consistent with the extension and retraction direction of the fork arm 232. In addition, the distance between the two sets of guide roller conveyors 52 can be adjusted by hand crank screw 53 to accommodate PACK100 of different sizes.

[0059] In this embodiment, the NG material rack 51 is a movable trolley mechanism. An NG positioning frame 54 is set at the NG diversion position to position the movable NG material rack 51. When the NG material rack 51 is full of defective PACKs, a new NG material rack 51 can be quickly replaced to ensure continuous operation of the production line.

[0060] refer to Figure 1 and Figure 17 Based on the above embodiments, the specific structure of the feeding and clustering unit 3 will be described in detail. The feeding and clustering unit 3 includes a clustering lifting mechanism 31, a clustering transverse movement mechanism 32, and a clustering plate chain mechanism 33. The bottom of the clustering lifting mechanism 31 is connected to the ground rail conveying mechanism 4.

[0061] The cluster entry lifting mechanism 31 is connected to the lifting frame 321 and is used to drive the lifting frame 321 to reciprocate vertically. Specifically, refer to... Figure 18 The clustering lifting mechanism 31 includes a second vertical frame 311, a second lifting motor 312, a steering reduction mechanism 313, and a lifting screw 314. The second lifting motor 312 is fixed to the top of the second vertical frame 311. The lifting frame 321 is fixedly connected to the lifting screw 314, and the lifting frame 321 is also slidably connected to the second vertical frame 311 via a linear module. The second lifting motor 312 drives the vertically positioned lifting screw 314 to rotate through the steering reduction mechanism 313, thereby causing the lifting frame 321 to move up and down in the vertical direction. This adjusts the height of the clustering transverse mechanism 32 and the clustering plate chain mechanism 33, facilitating docking with the electrical box transfer unit 2 for PACK transfer and adjusting to a specific height for clustering into the energy storage container PACK.

[0062] refer to Figure 19 The cluster-entry lateral movement mechanism 32 includes a lifting frame 321, a sliding plate frame 322 slidably connected to the upper part of the lifting frame 321 via a linear module, and a lateral movement frame 323 located below the lifting frame 321. A hanger 324 is movably inserted through the middle of the lifting frame 321. The sliding plate frame 322 and the lateral movement frame 323 are fixedly connected via the hanger 324, and the lateral movement frame 323 is slidably connected to the lifting frame 321 via a linear module. (Reference) Figure 20The lifting frame 321 is equipped with a horizontal transverse rack 325, the length direction of which is configured to be consistent with the movement direction of the transfer plate chain 243 transferring the PACK 100. The slide frame 322 is equipped with a transverse drive assembly 326 that meshes with the transverse rack 325. The transverse drive assembly 326 drives the slide frame 322 to move the transverse frame 323 relative to the lifting frame 321 through the meshing transmission of the transverse rack 325.

[0063] refer to Figure 20 and Figure 21 The clustering plate chain mechanism 33 includes a plate chain mounting base 331 and a clustering plate chain 332 mounted on a transverse frame 323. Both ends of the plate chain mounting base 331 are equipped with a second plate chain drive component 333 and two sets of sprockets 334 meshing with the clustering plate chain 332. The output end of the second plate chain drive component 333 drives the clustering plate chain 332 to rotate via the connecting sprockets 334, transporting the PACK 100 supported by the clustering plate chain 332 into the energy storage container.

[0064] In this embodiment, two sets of clustering plate chain mechanisms 33 are provided, located on the left and right sides inside the transverse frame 323, respectively, to support the PACK transferred from the electrical box transfer unit 2 and transport it to the container for clustering. To accommodate PACKs of different sizes and specifications and improve the stability of PACK transport, the spacing between the two sets of clustering plate chain mechanisms 33 can be freely adjusted. The plate chain mounting base 331 and the transverse frame 323 are slidably connected by multiple sets of linear modules. An adjustable pitch motor 327 is fixed on the transverse frame 323. The floating joint of the adjustable pitch motor 327 is connected to the plate chain mounting base 331 through an adjustable pitch screw 328 to achieve synchronous linkage. The two sets of adjustable pitch motors 327 drive their respective connected plate chain mounting bases 331 to move horizontally, thereby adjusting the spacing between the two sets of clustering plate chains 332.

[0065] refer to Figure 19 , Figure 21 and Figure 23 A set of pushing mechanisms 34 are respectively provided on the opposite outer sides of the clustering plate chain mechanism 33. The pushing mechanism 34 includes a second adjustable motor 341 fixed on the transverse frame 323, a second adjustable lead screw 342 connected to the output end of the second adjustable motor 341, and a pushing frame 343 connected to the second adjustable lead screw 342. A pushing motor 344 is fixed to one end of the pushing frame 343, and a pushing lead screw 345 is connected to the output end of the pushing motor 344. A connecting block 346 is threadedly connected to the pushing lead screw 345. The connecting block 346 and the pushing frame 343 are slidably connected through a horizontal linear module, and a vertically sliding slide cylinder 347 is installed on the connecting block 346. A horizontal pushing head 348 is connected to the slide cylinder 347.

[0066] refer to Figure 21The front and rear ends of the transverse frame 323 are respectively equipped with cylinder locking mechanisms 329. After the PACK is transferred to the top of the clustering plate chain 332, in order to prevent the PACK from slipping during the working movement of the clustering lifting mechanism 31 and the ground rail conveying mechanism 4, the cylinder locking mechanism 329 rises up to limit the front and rear ends of the PACK.

[0067] The working process of the feeding unit 3 is as follows: When the feeding plate chain mechanism 33 docks with the electrical box transfer unit 2, the PACK is transferred to the top of the feeding plate chain 332. Then, the cylinder locking mechanism 329 rises to limit the front and rear ends of the PACK. Next, the feeding lifting mechanism 31 and the ground rail conveying mechanism 4 adjust the container feeding position of the PACK in the vertical and horizontal directions. When the container feeding operation is performed, the feeding plate chain 332 drives the PACK to move backward. At the same time, the adjusting motor 341 drives the adjusting screw 342 to drive the feeding frame 343 to move from both sides to approach the PACK. The slide cylinder 347 adjusts the height of the feeding head 348 to correspond to the PACK. The feeding motor 344 drives the feeding head 348 to move along the feeding screw 345, thereby abutting and pushing the PACK to move backward into the cluster.

[0068] like Figure 24 and Figure 25 As shown, based on the above embodiments, the automatic clustering device for energy storage container PACK also includes a door opening mechanism 7, which is used to automatically open the container door.

[0069] The door opening mechanism 7 includes a support frame 71 located around the periphery of the energy storage container, a suspension beam 72 disposed above the support frame 71, and at least one set of automatic door opening components 73 disposed on the suspension beam 72. The automatic door opening component 73 includes a base 731 slidably connected to the suspension beam 72, a moving motor 732 and a primary rotary motor 733 fixed to the base 731, a mounting frame 734 connected to the output end of the primary rotary motor 733, a sliding frame 735 slidably connected below the mounting frame 734, a secondary rotary motor 736 fixedly connected to the sliding frame 735, a rotating link 737 rotatably connected to the sliding frame 735, and a door suction component 738 connected to the bottom end of the rotating link 737. The moving motor 732 moves horizontally along the length of the suspension beam 72 via a rack and pinion mechanism 739, and the secondary rotary motor 736 drives the rotating link 737 to rotate around its own axis via a belt drive.

[0070] The door suction assembly 738 includes a suction cylinder 7381 fixed to the bottom end of a rotating connecting rod 737, a door suction bracket 7382 slidably connected to the bottom end of the rotating connecting rod 737, and a sponge suction cup 7383 fixed to the side of the door suction bracket 7382. The floating joint of the suction cylinder 7381 is connected to the door suction bracket 7382, and the sponge suction cup 7383 can prevent damage to the container door while fixing it.

[0071] The energy storage container is carried into the station by an AGV / RGV, positioned by a trolley positioning mechanism 8, and the container door is automatically opened by a door opening mechanism 7 to allow the PACK to be clustered.

[0072] When the door opening mechanism 7 is working: the moving motor 732 drives the base 731 to slide along the suspension beam 72 through the gear and rack mechanism 739, roughly positioning the entire door opening assembly directly above the container door lock bar; the first-stage rotary motor 733 drives the mounting frame 734 to rotate, causing the door opening mechanism 7 below to swing to a suitable working angle; at the same time, the suction cylinder 7381 extends, pushing the door suction bracket 7382 to slide, so that the sponge suction cup 7383 is tightly attached to and negatively adsorbed onto the surface of the container door panel; then the second-stage rotary motor 736 drives the rotating connecting rod 737 to rotate around its own axis through belt transmission, while the first-stage rotary motor 733 rotates in the opposite direction, thereby driving the adsorbed container door to rotate around the door axis through the mounting frame 734 and the sponge suction cup 7383, automatically opening the container door.

[0073] refer to Figure 1 and Figure 10 Based on the above embodiments, the specific structure of the ground rail conveying mechanism 4 will be described in detail. Each set of ground rail conveying mechanisms 4 includes two parallel ground rails 41 fixed to the ground, a ground rail support plate 42 slidably connected above the ground rails 41, a ground rail motor 43 mounted on the ground rail support plate 42, and a track rack 44 parallel to and fixed to the side of the ground rails 41. The output shaft of the ground rail motor 43 is connected to the track rack 44 through a coaxially connected gear.

[0074] In the electrical box transfer unit 2, the bottom of the height adjustment mechanism 21 is fixedly connected to the ground rail support plate 42. The ground rail motor 43 drives the ground rail support plate 42 to carry the electrical box transfer unit 2 along the ground rail 41 via gear transmission, which is used to adjust the working position of the electrical box transfer unit 2. In the material feeding unit 3, the bottom of the feeding lifting mechanism 31 is fixedly connected to the ground rail support plate 42. The ground rail motor 43 drives the ground rail support plate 42 to carry the material feeding unit 3 along the ground rail 41 via gear transmission, which is used to adjust the working position of the material feeding unit 3. The two sets of ground rail conveying mechanisms 4 are controlled independently and can be adjusted to the optimal working position according to the operation needs without interfering with each other.

[0075] The central control system of this invention uses an industrial-grade PLC as the core control unit, and is used in conjunction with an industrial touch screen to realize human-machine interaction. The central control system communicates with the electrical box material rack lifting unit 1, electrical box transfer unit 2, material pushing and clustering unit 3, two sets of ground rail conveying mechanisms 4, code reading mechanism 6, and door opening mechanism 7 via industrial Ethernet or fieldbus.

[0076] The automatic clustering device for energy storage container PACK of the present invention is also equipped with protective fences, control cabinets, roller shutters and other supporting facilities to ensure safe operation of the equipment, facilitate maintenance and management, and achieve effective isolation and dust protection of the work area.

[0077] Another embodiment of the present invention also provides an automatic clustering method for an energy storage container PACK based on the automatic clustering device described in the above embodiments, comprising the following steps: S1, Material rack receiving and separation lifting: The electrical box rack lifting unit 1 receives a rack carrying at least one PACK and lifts the rack frame separately from the PACK, so that the PACK is at the material picking height.

[0078] S2, PACK material retrieval: The electrical box transfer unit 2 is driven by the ground rail conveyor mechanism 4 to move horizontally to the material picking position of the electrical box material rack lifting unit 1, and the electrical box transfer unit 2 picks up the lifted PACK.

[0079] S3, PACK forwarding: The ground rail conveyor 4 drives the transfer unit 2 carrying the electrical box to move horizontally to the feeding unit 3, and transports the acquired PACK to the feeding unit 3.

[0080] S4, Cluster entry position adjustment and material pushing: Another set of ground rail conveying mechanisms 4 drives the material pushing and clustering unit 3 to move horizontally to the clustering port of the energy storage container, and the material pushing and clustering unit 3 transfers the received PACK to the target position inside the energy storage container.

[0081] S5, Cooperative beat control: The central control system controls the electrical box material rack lifting unit 1, electrical box transfer unit 2, material pushing and clustering unit 3, and two sets of ground rail conveying mechanisms 4 to work together according to the preset rhythm, and executes steps S1 to S4 in a loop until all PACKs are automatically clustered.

[0082] The central control system monitors the working status of each unit in real time through communication connections and coordinates the action sequence of each unit according to preset cycle parameters to achieve multi-station parallel operation. When a PACK completes its clustering, the system automatically enters the clustering cycle of the next PACK until all cluster rack positions in the energy storage container are filled.

[0083] Although the preferred embodiments of the present invention have been disclosed above, they are not intended to limit the present invention. Any person skilled in the art can make possible changes and modifications to the technical solutions of the present invention by utilizing the methods and techniques disclosed above without departing from the spirit and scope of the present invention. Therefore, any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the content of the technical solutions of the present invention shall fall within the protection scope of the technical solutions of the present invention.

Claims

1. An automatic clustering device for an energy storage container PACK, characterized in that, It includes an electrical box material rack lifting unit (1), an electrical box transfer unit (2), a material pushing and clustering unit (3), two sets of ground rail conveying mechanisms (4), and a central control system; The electrical box rack lifting unit (1) is used to receive a multi-layer rack carrying a PACK and to lift the rack frame separately from the PACK. The electrical box transfer unit (2) is used to obtain the PACK from the material picking position of the electrical box rack lifting unit (1) and transport the qualified PACK to the material pushing and clustering unit (3). The push-in cluster unit (3) is used to receive the PACK delivered by the electrical box transfer unit (2) and transfer the PACK to the target position inside the energy storage container; The two sets of ground rail conveying mechanisms (4) are configured to carry the electrical box transfer unit (2) and the material pushing and clustering unit (3) respectively, and move horizontally back and forth along their respective ground rails to adjust the working position; The overall control system is connected to the electrical box material rack lifting unit (1), electrical box transfer unit (2), material pushing into cluster unit (3), and two sets of ground rail conveying mechanisms (4) and controls each unit mechanism to coordinate its actions according to a preset rhythm. The coordinated actions include at least the following: while the electrical box rack lifting unit (1) lifts the rack frame and PACK separately, the central control system controls a set of ground rail conveying mechanisms (4) to drive the electrical box transfer unit (2) to move to the material picking position; during the process of the electrical box transfer unit (2) acquiring the PACK and conveying it to the material pushing and clustering unit (3), the central control system controls another set of ground rail conveying mechanisms (4) to drive the material pushing and clustering unit (3) to move to the energy storage container's inlet; the electrical box rack lifting unit (1), electrical box transfer unit (2), material pushing and clustering unit (3) and the two sets of ground rail conveying mechanisms (4) execute their respective processes in parallel under the control of the central control system to achieve multi-station parallel operation.

2. The automatic clustering device for energy storage container PACKs according to claim 1, characterized in that, The electrical box rack lifting unit (1) includes a positioning mechanism (11) and two lifting mechanisms (12) located on both sides of the rack and working in sync. The positioning mechanism (11) is used to guide the rack loaded with PACK into the working position and to position the rack. The lifting mechanism (12) includes a lifting frame (121) and a lifting drive mechanism (122), a lower lifting component (123), an upper lifting component (124), a transverse drive mechanism (125), and a first lifting mechanism (126) connected to the lifting frame (121). The lifting drive mechanism (122) is configured to drive the lower lifting member (123) to rise and fall in the vertical direction while simultaneously driving the upper lifting member (124) to move synchronously. The lower lifting member (123) and the upper lifting member (124) are respectively connected to a set of material carrier plates (127) on the side near the material rack. The transverse drive mechanism (125) is configured with two sets and drives the two sets of material carrier plates (127) to move independently in the horizontal direction, so as to abut and support the PACK or material rack frame located at different height layers. The first lifting mechanism (126) is used to drive the upper lifting member (124) to move vertically relative to the lower lifting member (123) and adjust the distance between the upper and lower sets of material carrier plates (127).

3. The automatic clustering device for energy storage container PACKs according to claim 2, characterized in that, The electrical box rack lifting unit (1) also includes a plurality of folding leg mechanisms (13) disposed around the rack. The folding leg mechanism (13) includes a folding leg frame (131), a lifting mechanism (132) vertically disposed on the folding leg frame (131), a transverse movement mechanism (133) connected to the lifting mechanism (132), and a clamping mechanism (134) and a rotating mechanism (135) disposed on the transverse movement mechanism (133). The clamping mechanism (134) is used to clamp the legs of the single-layer material rack frame; the lifting mechanism (132) is used to drive the lateral movement mechanism (133) to drive the clamping mechanism (134) to reciprocate in the vertical direction; the lateral movement mechanism (133) is used to drive the clamping mechanism (134) to reciprocate in the horizontal direction; the rotating mechanism (135) converts the linear driving force into rotational motion to drive the legs of the material rack frame clamped by the clamping mechanism (134) to rotate and fold.

4. The automatic clustering device for energy storage container PACKs according to claim 1, characterized in that, The electrical box transfer unit (2) includes a height adjustment mechanism (21), a lifting frame (22) connected to the height adjustment mechanism (21), a fork arm mechanism (23) provided on the lifting frame (22), and two sets of plate chain transfer mechanisms (24) provided on the fork arm mechanism (23) facing outwards. The bottom of the height adjustment mechanism (21) is connected to the ground rail conveying mechanism (4) to drive the lifting frame (22) to move in the vertical direction; The fork arm mechanism (23) includes a fork arm drive (231) connected to the lifting frame (22) and at least two sets of fork arms (232) connected to the fork arm drive (231). The plate chain transfer mechanism (24) includes a plate chain bracket (241) fixed on the lifting frame (22), a plate chain drive component (242) provided on the plate chain bracket (241), and a transfer plate chain (243) driven by the plate chain drive component (242) and rotating around the plate chain bracket (241). The transfer plate chain (243) is aligned with the length direction of the fork arm (232).

5. The automatic clustering device for energy storage container PACKs according to claim 4, characterized in that, The plate chain transfer mechanism (24) is also provided with a second lifting mechanism (25). The second lifting mechanism (25) includes a push-pull cylinder (251) fixed on the lifting frame (22) and two wedge blocks (252) that are horizontally slidably connected to the lifting frame (22). The two wedge blocks (252) are connected by a connecting rod (253) and move in the same direction. One of the wedge blocks (252) is connected to the floating joint of the push-pull cylinder (251) to achieve synchronous linkage. The plate chain bracket (241) is connected to a roller support (254), and at least two sets of rollers (255) are connected below the roller support (254). The wedge surface above each wedge block (252) abuts against at least one roller (255). A guide rail seat (256) is also vertically installed on the lifting frame (22). The roller support (254) and the guide rail seat (256) are vertically slidably connected by a linear module.

6. The automatic clustering device for energy storage container PACKs according to claim 1, characterized in that, Downstream of the electrical box transfer unit (2) is an NG diversion unit (5). The NG diversion unit (5) includes an NG material rack (51) and two sets of guide rollers (52) slidably connected to the top of the NG material rack (51). The top of the NG material rack (51) is provided with two sets of hand crank screws (53). The two sets of guide rollers (52) are respectively connected to one set of hand crank screws (53) by thread engagement. The electrical box transfer unit (2) is equipped with a code reading mechanism (6) that is connected to the main control system. It is used to read the identity code after the electrical box transfer unit (2) obtains the PACK. PACKs that fail the code reading are transferred to the guide roller (52) of the NG material rack (51) through the electrical box transfer unit (2) for NG diversion.

7. The automatic clustering device for energy storage container PACKs according to claim 1, characterized in that, The feeding unit (3) includes a feeding lifting mechanism (31), a feeding transverse movement mechanism (32) and a feeding plate chain mechanism (33). The bottom of the feeding lifting mechanism (31) is connected to the ground rail conveying mechanism (4). The cluster entry lateral movement mechanism (32) includes a lifting frame (321), a sliding plate frame (322) slidably connected above the lifting frame (321), and a lateral movement frame (323) located below the lifting frame (321). A hanger (324) is movably provided through the middle of the lifting frame (321). The sliding plate frame (322) and the lateral movement frame (323) are fixedly connected by the hanger (324). A horizontal lateral movement rack (325) is provided on the lifting frame (321), and a lateral movement drive assembly (326) is provided on the sliding plate frame (322) and meshes with the lateral movement rack (325). The cluster entry lifting mechanism (31) is connected to the lifting frame (321) and is used to drive the lifting frame (321) to reciprocate in the vertical direction; The clustering plate chain mechanism (33) includes a plate chain mounting base (331) and a clustering plate chain (332) mounted on a transverse frame (323). Both ends of the plate chain mounting base (331) are provided with a plate chain drive component (333) and two sets of sprockets (334) meshing with the clustering plate chain (332). The output end of the plate chain drive component (333) drives the clustering plate chain (332) to rotate through the connecting sprockets (334), thereby transporting the PACK supported by the clustering plate chain (332) to the energy storage container.

8. The automatic clustering device for energy storage container PACKs according to claim 6, characterized in that, The clustering plate chain mechanism (33) is provided with a set of pushing mechanisms (34) on the opposite outer side. The pushing mechanism (34) includes a second adjustable motor (341) fixed on the transverse frame (323), a second adjustable screw (342) connected to the output end of the second adjustable motor (341), and a pushing frame (343) connected to the second adjustable screw (342). One end of the pusher frame (343) is fixed with a pusher motor (344), the output end of the pusher motor (344) is connected to a pusher screw (345), a connecting block (346) is threaded on the pusher screw (345), the connecting block (346) is slidably connected to the pusher frame (343), and a vertically sliding slide cylinder (347) is installed on the connecting block (346), and a horizontal pusher head (348) is connected to the slide cylinder (347).

9. The automatic clustering device for energy storage container PACKs according to claim 1, characterized in that, It also includes a door opening mechanism (7) for automatically opening the container door; The door opening mechanism (7) includes a support frame (71) located around the energy storage container, a suspension beam (72) located above the support frame (71), and at least one set of automatic door opening components (73) located on the suspension beam (72). The automatic door opening assembly (73) includes a base (731) slidably connected to the suspension beam (72), a moving motor (732) and a first-stage rotary motor (733) fixed on the base (731), a mounting bracket (734) connected to the output end of the first-stage rotary motor (733), a sliding frame (735) slidably connected to the bottom of the mounting bracket (734), a second-stage rotary motor (736) fixedly connected to the sliding frame (735), a rotating link (737) rotatably connected to the sliding frame (735), and a door suction assembly (738) connected to the bottom end of the rotating link (737). The moving motor (732) moves horizontally along the length direction of the suspension beam (72) through a gear and rack mechanism (739), and the second-stage rotary motor (736) drives the rotating link (737) to rotate through a belt drive. The door suction assembly (738) includes a suction cylinder (7381) fixed to the bottom end of the rotating link (737), a door suction bracket (7382) slidably connected to the bottom end of the rotating link (737), and a sponge suction cup (7383) fixed to the side of the door suction bracket (7382).

10. A method for automatic clustering of an energy storage container PACK based on the automatic clustering device according to any one of claims 1 to 9, characterized in that, Includes the following steps: S1, Material rack receiving and separation lifting: The material rack carrying at least one PACK is received by the electrical box material rack lifting unit (1), and the material rack frame is lifted separately from the PACK so that the PACK is at the material picking height; S2, PACK material retrieval: The electrical box transfer unit (2) is driven to move horizontally to the material picking position of the electrical box material rack lifting unit (1) by the ground rail conveying mechanism (4), and the electrical box transfer unit (2) obtains the lifted PACK; S3, PACK forwarding: The ground rail conveyor (4) drives the transfer unit (2) carrying the electrical box to move horizontally to the feeding unit (3) and transports the acquired PACK to the feeding unit (3). S4, Cluster entry position adjustment and material pushing: Another set of ground rail conveying mechanism (4) drives the material pushing and clustering unit (3) to move horizontally to the clustering port of the energy storage container, and the material pushing and clustering unit (3) transfers the received PACK to the target position inside the energy storage container. S5, Cooperative beat control: The main control system controls the electrical box material rack lifting unit (1), electrical box transfer unit (2), material pushing into cluster unit (3) and two sets of ground rail conveying mechanisms (4) to work together according to the preset rhythm, and executes steps S1 to S4 in a loop until all PACKs are automatically clustered.

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