Assembly line and process for the manufacture of modules or module precursors

Abstract

An assembly line comprises a transport track to convey first, second, and third workpiece carriers through process stations. Each first workpiece carrier is designed and configured to receive at least one first electrode stack, one second electrode stack, and a supplied cover onto a support on the workpiece carrier and secure them as a package at the first process station. The electrode stacks and the cover, with their associated positive and negative poles and respective contacts, make contact with the first and second terminals of the two electrode stacks. The secured package is then conveyed to a measuring station to determine its position and orientation on the support and to signal this information to the transport track's control system. The package is then conveyed to a trimming station to trim the first and second terminals of the electrode stacks and the contacts of the cover.The package is fed to a connecting station to connect the first and second terminals of the electrode stacks and the respective contacts of the cover. The package is then transferred to one of the second workpiece carriers in the second process station. Each of the second workpiece carriers then sends the package to an inspection station to check its properties and manufacturing details, then to an insulation station to electrically insulate at least some of the package, and finally transfers the package to one of the third workpiece carriers in the third process station.Each of the third workpiece carriers receives a housing on a support of the third workpiece carrier, guides the insulated package from the second workpiece carrier to an enclosure into an insertion opening of the housing on a support of the third workpiece carrier, so that the lid covers the insertion opening of the housing, and guides the housing with the lid to a closing device to connect the lid to the insertion opening of the housing in such a way that the lid closes the insertion opening, guides the housing with the package to a testing device to X-ray the package and the housing for image acquisition and signal the image acquisition to the control system of the transport line for evaluation, and guides the housing with the lid and the package to a leak test to check the housing with the lid for gas tightness and signal the result to the control system of the transport line.

Description

background

[0001] This document discloses an assembly line and a method for manufacturing modules or module precursors, in particular layered material and / or fuel or battery cells. Details are defined in the claims; however, the description also contains relevant information on the structure and operation as well as on variants of the method and the device components. State of the art

[0002] In conventional fuel cell or battery cell manufacturing, the machines performing the respective process steps are operated as individual machines (so-called stand-alone units). This applies, for example, to the stacking of electrodes in a stacking machine, the pressing of the loose electrode stack under high pressure and high temperatures in a block lamination machine, and other process machines such as those used for welding the electrical connection tabs. Each processing station at the different manufacturing stages of the workpiece (e.g., cell stack) has its own transport system (feed, processing, and removal). Data processing (detection of the workpiece to be processed, acquisition of relevant workpiece data, image acquisition, or measurement data, e.g., for quality control, etc.) takes place within and by the processing station itself.Each processing station has its own process computer capacity and communicates with the control system to ensure orderly transport to the next processing station. Operating several separate machines in sequence leads to variations in manufacturing precision and delays during the transfer of the respective intermediate product from one machine to the next. This can result in significant fluctuations in product quality.

[0003] JP 2020 138 854 A relates to a laminating device with a feeder that supplies a film body; a pallet that is transported along a conveyor; the film body supplied by the feeder is laminated on the pallet. A guide rail is provided along the conveyor.

[0004] EP 3 424 075 B1 relates to a handling system with a rail and independent and coordinated shuttles for industrial automation, powered by a linear motor with an electromagnetic drive. The shuttles engage with the same rail and move along it while performing their function. Each shuttle has a feed mechanism for moving along the rail, along with processing and control means. The system coordinates the shuttles' activities, including means for determining their position, means for sending and receiving information, and centralized processing and control means. The system uses a linear synchronous motor with motion coils to advance the shuttles.Permanent magnets are integrated into the track to interact with coils on each shuttle, allowing the shuttles to move and perform functions independently. This also enables individual shuttles to be added or removed from the system. Each shuttle is wirelessly connected for information transmission, using either sliding contacts or wireless electromagnetic induction for power. Automatic positioning systems continuously communicate along the track with a reference reader attached to each shuttle. The system has a central control and processing unit with a central server. This server contains control logic and executable programs configured to process information received from the simultaneously active shuttles and the sensors.The shuttles are moved synchronously and / or asynchronously on the same track in an independent but coordinated manner. Each shuttle has a self-propelled sliding shoe as a pusher, which is detachably attached to the track and includes all active means for carrying out the forward motion along the track. These are the primary motion control and communication means. Each sliding shoe is autonomous and independent, including the onboard coils, which are selectively controlled for the purpose of electromagnetic propulsion, as well as their control unit, sensors, and means for receiving and transmitting information. Each shuttle is wirelessly connected for power supply and data transmission.The sliding shoe has means for wireless power supply from the rail, movable coils, a logic control unit to manage the primary motion for the entire path, means for generating pressure or vacuum, for example a vacuum pump or a pump with a Venturi device with interfaces, an integrated circuit to manage communication with access ports for software updates or control diagnostics, an antenna for wireless communication, for example for updating data, tasks or positions, collision sensor means to prevent collisions of shuttles, transducer means with position sensors for the fixed, continuous and absolute reference located in the rail, or absolute encoders for micrometric position control, and means for high-speed proximity communication.The rail includes a power supply with a fixed power line, which is to be transmitted to the moving shuttles in two alternative ways: by contact or without contact using electromagnetic induction devices, in which, instead of brushes, some receivers are attached to the shuttles; fixed permanent magnets to link the magnetic flux of the linear motor coils on the shuttles; a fixed magnetic line to provide the position sensors on the shuttles with an absolute reference; and a signal line for data and communication to and from the moving shuttles. The self-propelled sliding shoe has means for activating the secondary drives with drive means for actuating the secondary drives, such as driving extraction lifting devices or controlling the inclination of the devices. The means form a shell for holding and positioning a photovoltaic cell for the operation of the secondary drives.These are removable devices connected to the self-propelled shuttle and can be detached on command from the shuttle or the central server. Depending on the planned task, specific coding, traffic conditions, or accidents, the shuttle functions as either a captain or a slave.The rail is a linear and compact, bidirectional, double-sided integrated rail comprising an upper rail positioned above a lower rail, which are integrated together, with lateral tilting, the lateral tilting being accomplished by a tilting device with a rotary motor configured to tilt an entire section of the rail including guides, magnets and power supply, so that the shuttle engaging the upper rail is tilted 180° to pick up a section of the lower rail, and vice versa from bottom to top, or to make partial rotations, for example 90°, to travel onto another rail section.

[0005] DE 10 2022 102 829 A1 comprises an assembly line for the production of modules or module precursors, in particular fuel or battery cells containing layered material and / or fluid. A central transport line is provided and configured to convey a large number of workpiece carriers between several process stations on a forward and a return journey. On the forward journey, the central transport line includes a first transport section for conveying / positioning one or more workpiece carriers to / in a first process station, and a second transport section for conveying / positioning one or more workpiece carriers to / in another process station. On the return journey, the central transport line includes a third transport section for conveying one or more workpiece carriers from a final process station to the first process station.The central transport line is designed to convey the workpiece carriers in groups, at least in some of its transport sections. A first process station, designed as a stacking station, is provided and configured to remove one or more workpiece carriers from the central transport line. The stacking station is configured to alternately stack individual anode layers from a first side of the workpiece carrier and individual cathode layers from a second side of the workpiece carrier onto at least one workpiece carrier taken from the central transport line, forming an electrode stack on the respective workpiece carrier. The first and second sides of the workpiece carrier can be opposite each other, for example, in the conveying direction of the workpiece carrier from both longitudinal sides of the central transport line.The stacking station is designed to return one or more workpiece carriers, each carrying a stack of electrodes, to the central transport track. A further process station, designed as a lamination station, is provided and configured to treat a workpiece carrier with a stack of electrodes, transported from the respective stacking point of the stacking station along the central transport track, with pressure and / or heat so that the individual anode and cathode layers form a bond. Technical problem

[0006] Based on this situation, a cost-effective and robust arrangement and procedure with high processing speed should be provided in order to manufacture modules or precursors of modules, in particular fuel or battery cells containing layered material. Proposed solution

[0007] To solve this problem, an assembly line and a method are proposed according to the independent claims. Further developments and variants are the subject of the dependent claims.

[0008] An assembly line comprises a transport track to convey first, second, and third workpiece carriers through process stations. Each first workpiece carrier is designed and configured to receive at least one first electrode stack, one second electrode stack, and one cover on a support of the workpiece carrier and secure them as a package at the first process station. The electrode stacks and the cover, with their associated positive and negative poles and respective contacts, make contact with the first and second terminals of the two electrode stacks. The secured package is then fed to a measuring station to determine its position and orientation on the support and to signal this information to the transport track's control system. The package is then fed to a trimming station to trim the first and second terminals of the electrode stacks and the contacts of the cover.The package is fed into a connector to connect the first and second terminals of the electrode stacks and the respective contacts of the cover.

[0009] The package is transferred to one of the second workpiece carriers in the second process station. Each of the second workpiece carriers then passes the package to an inspection station to check its properties and manufacturing details, passes the inspected package to an insulation station to electrically insulate at least parts of it, and then transfers the package to one of the third workpiece carriers in the third process station.Each of the third workpiece carriers receives a housing on a support of the third workpiece carrier, guides the insulated package from the second workpiece carrier to an enclosure into an insertion opening of the housing on a support of the third workpiece carrier, so that the lid covers the insertion opening of the housing, and guides the housing with the lid to a closing device to connect the lid to the insertion opening of the housing in such a way that the lid closes the insertion opening, guides the housing with the package to a testing device to X-ray the package and the housing for image acquisition and signal the image acquisition to the control system of the transport line for evaluation, and guides the housing with the lid and the package to a leak test to check the housing with the lid for gas tightness and signal the result to the control system of the transport line.

[0010] Such an assembly line for the production of modules or precursors of layered material fuel or battery cells includes a transport route designed and equipped to convey workpiece carriers between process stations.

[0011] This assembly line includes a transport route designed to convey first, second and third workpiece carriers through process stations along the transport route.

[0012] In one variant of the assembly line, a data storage unit is provided in the control system of the transport route to store identifiable characteristics in the form of QR®, number, bar and / or similar codes assigned to the workpiece carriers for the purpose of tracing the modules and their precursors, together with recorded process data such as position data, measurement data, location and orientation of the modules or their precursors on the workpiece carriers.

[0013] Each of the first workpiece carriers in this assembly line is provided and equipped to receive at least one first electrode stack, one second electrode stack, and one cover with associated positive and negative poles and respective contacts, which are supplied to the first workpiece carrier and are supplied to the first workpiece carrier for the two electrode stacks, mechanically and electrically contact a respective first and a respective second connecting tab of the two electrode stacks, place them on a support of the workpiece carrier and fix them as a package in a first process station.

[0014] Each of the first workpiece carriers in this assembly line is designed and equipped to feed the fixed package to a measuring device, to measure the position and orientation of the electrode stack on the support of the workpiece carrier, and to signal this information to a control system for the transport route.

[0015] Each of the first workpiece carriers in this assembly line is designed and equipped to feed the package to a trimming unit, designed and equipped to trim the first and second connection tabs of the electrode stacks as well as the contacts of the cover.

[0016] Each of the first workpiece carriers in this assembly line is designed and equipped to feed the package to a joining process, and is designed and equipped to mechanically and electrically connect the first and second connecting tabs of the electrode stacks as well as the respective contacts of the cover to each other.

[0017] In one variant, the trimming and connecting of the first and second terminals of the two electrode stacks, as well as the contacts of the cover, is performed using a laser. Different lasers can be used. In another variant, the trimming and connecting are carried out with the same laser, operated with different parameters. In the latter case, the first workpiece carrier is not moved relative to the transport path.

[0018] The first workpiece carriers are provided in this assembly line and configured to transfer the package to one of the second workpiece carriers in the second process station. In one variant, the package is transferred in such a way that it is firmly clamped between two or more fingers on the second workpiece carrier and hangs freely.

[0019] Each of the second workpiece carriers in this assembly line is designed and configured to deliver the package to the second process station, which follows the first, for inspection. This inspection assesses the package's properties and manufacturing details. In one version of the assembly line, this inspection (capturing and evaluating position data, measurement data, location, and orientation of the modules or their precursors on the workpiece carrier) is performed tactilely and / or using imaging. The inspection results are communicated to the transport system's control unit and stored by the control unit along with the identifiable characteristic assigned to the respective workpiece carrier.

[0020] Each of the second workpiece carriers in this assembly line is designed and configured to feed the inspected package to an insulating process, and to electrically insulate the package, at least partially. In one variant of this insulating process, the package held by the second workpiece carrier is inserted into a plastic pocket (polyethylene, polypropylene, etc.), or the plastic pocket is placed over the package (from below). Alternatively, the package held by the second workpiece carrier is wrapped with a plastic film. In one variant, the support with the package is rotated around a rotation axis of the support relative to a feeder for the plastic film. In another variant, the plastic film is wrapped around the stationary package on the support.

[0021] Each of the second workpiece carriers in this assembly line is designed and configured to transfer the package to one of the third workpiece carriers in the third process station. In one variant, the second workpiece carrier is aligned with the third workpiece carrier, and then the package held by the second workpiece carrier is lowered onto the third workpiece carrier.

[0022] Each of the third workpiece carriers is provided in this assembly line and is designed to receive a housing on a support of the third workpiece carrier in the third process station, which follows the second process station.

[0023] Each of the third workpiece carriers is provided in this assembly line and is designed to receive the package of the two electrode stacks and the lid from one of the second workpiece carriers into an insertion opening of the housing on a support of the third workpiece carrier, so that the lid covers the insertion opening of the housing.

[0024] Each of the third workpiece carriers in this assembly line is designed and configured to feed the housing with the lid to a sealing process, and to connect the lid to the housing's insertion opening in such a way that the lid seals the insertion opening gas-tight and / or liquid-tight. This can be achieved, for example, by (laser) welding, folding, flanging, or similar processes.

[0025] Each of the third workpiece carriers in this assembly line is designed and equipped to feed the housing with the package to a test, designed and equipped to X-ray the package and the housing for an image acquisition and to signal the image acquisition to the control of the transport route for evaluation.

[0026] Each of the third workpiece carriers in this assembly line is designed and equipped to feed the housing with the lid and the package to a leak test, to test the housing with the lid for gas tightness and to signal the result to the control of the transport route.

[0027] In one variant, the assembly line includes a stacking station on the upstream side of the first process station, designed and equipped to stack individual anode foil layers and individual cathode foil layers and / or individual separating foil layers to form a first or second electrode stack on the first or a workpiece carrier.

[0028] In one variant, a lamination point is provided downstream of the stacking point and is set up to treat a workpiece carrier coming from the stacking point with the electrode stack with pressure and / or heat so that the anode, cathode and / or separating film layers form a bond.

[0029] In one variant of the assembly line, the workpiece carriers are provided with uniquely identifiable features, which are detected by corresponding sensors on the transport route and signaled to the control system of the transport route.

[0030] In one variant of the assembly line, the control system for the transport route is designed and configured to process the captured characteristics of the workpiece carriers together with the data on the position and orientation of the electrode stack on the support of the workpiece carrier, and / or the image acquisition and / or the result of the gas tightness in the control system for the transport route.

[0031] In one variant of the assembly line, the identification of the individual workpiece carriers takes place at the entrance of each process station, and / or the recording of the process data takes place at the respective process point.

[0032] In one variant, the position and orientation of the housing on the support of the third workpiece carrier are measured, for example by means of imaging or tactilely, and its serial number is determined, for example by means of imaging, in addition to the insertion opening of the housing on the support of the third workpiece carrier.

[0033] In one version of the transport system, a serial number of the housing is stored. When the package is transferred from the second workpiece carrier to the housing on the support of the third workpiece carrier, the data relating to the package from the second workpiece carrier is added to the data of the third workpiece carrier. This ensures continuous traceability of the individual product and its production process.

[0034] In one variant of the assembly line, at least the support of the first workpiece carrier can be swivelled out of a plane of the workpiece carrier by at least approximately 70–110°, for example, 90°. This facilitates imaging, trimming, joining / welding, or other processing of the package or housing, with or without the package inside.

[0035] In one variant of the assembly line, the support of the workpiece carrier has openings and / or recesses to provide access to the stack of electrodes located on the support of the workpiece carrier.

[0036] In one variant of the assembly line, the first, second, or third workpiece carriers have one or more clamps arranged and configured to clamp the electrode stacks, housings, etc. located on the support of the workpiece carrier, each clamp having a clamping jaw provided and configured to clamp the electrode stack firmly in a first position and to release the electrode stack on the workpiece carrier in a second position.

[0037] Such an assembly line, with its workpiece carriers, allows the individual process stations to interact and operate automatically. The workpiece carriers, with their structures dedicated to the electrode stacks and the respective process requirements (e.g., supports and clamps for the electrode stacks, packages, or housings), make it possible to manage with a small number of process stations. This allows for a simpler system design (including space and footprint requirements) than previous solutions.

[0038] Currently, each workpiece processing station (electrode stack) has its own transport system (feed, processing, and removal). Data processing (detection of the workpiece to be processed, recording of relevant workpiece data, image acquisition, or measurement data, e.g., for quality control, etc.) takes place within and by the processing station itself. Each processing station has its own dedicated computer capacity and communicates with the control system to ensure orderly transport to the next processing station.

[0039] The solution presented here is based on an assembly line with a continuous linear workpiece transport path, along which individual process stations are arranged, and which features a path control system. This system coordinates the individual process stations as subsystems of the workpiece transport path. This allows for optimized linking of the process steps performed in the individual process stations and their sequence. Performing two or more process steps in a single processing station reduces the transport steps between the individual process stations and the associated transfer of workpieces from one process station to the next.

[0040] At the end of the transport route, in one variant of the assembly line, the workpiece carriers are unloaded for return transport. Beforehand, the electrode packages requiring further processing or inspection are removed from the workpiece carriers in their housings, for example, using a pick-and-place process. The empty workpiece carriers are then returned to the beginning of the transport route. In one variant, all workpiece carriers are marked with uniquely identifiable features. Corresponding sensors along the transport route allow for comprehensive traceability of the modules and their precursors for storing the respective data. These identifiable features include QR codes, numerical codes, barcodes, and / or similar codes. The identification of each individual workpiece carrier and the workpiece it contains can take place at the entrance of each process station or within each process station itself.

[0041] Preparatory measures required for a new process step, such as clamping, measuring, and unclamping the electrode stack, can be at least partially eliminated. The solution presented here allows for an overall increase in the processing rate of the workpieces.

[0042] The multifunctional workpiece carriers act together with the workpiece transport system as a master, so that the individual process stations do not operate in isolation from each other and do not have to be connected first; rather, an integrated network of the process stations is realized through the workpiece carriers with the workpiece transport system.

[0043] The workpiece transport system is linear; rotary tables for the workpiece carriers that circulate the workpieces are not required. This also facilitates simpler parallelization for the required traceability and easier documentation of the individual process steps, including the coding of the workpiece carriers.

[0044] After stacking the anode, separator, and cathode foils to form the electrode stack, no further transfer of the electrode stack to another workpiece carrier is necessary. The subsequent process steps up to and including wrapping with insulating material can be performed on the same workpiece carrier.

[0045] In one variant of the assembly line, a first cutting or punching station is set up to form the electrode stack. This station cuts a first continuous layer of material and delivers it, for example, as individual anode foil layers to the stacking point. A second cutting or punching station cuts a second continuous layer of material and delivers it, for example, as individual cathode foil layers to the stacking point. Similarly, a third cutting or punching station cuts a third continuous layer of material and delivers it, for example, as individual separator foil layers to the stacking point.

[0046] The electrode stacks, wrapped in insulating material, can be inserted directly into the housing mounted on one of the third workpiece carriers.

[0047] Through 2D or 3D computed tomography (CT) scans or X-ray radiography for quality analysis, the internal structures of the electrode stacks, their connections, and the connection between the lid and the housing are visualized. These examinations, as well as leak tests of the welded housings using, for example, helium, can be performed before final process steps and inspections are carried out in the drying chamber. This allows for a more compact drying chamber.

[0048] In one variant of the assembly line, the workpiece carriers are returned downstream to each process station, for example, to remove the electrode stacks if a defect in the respective module or its precursors is detected. In another variant, the workpiece carriers are returned at the end of the transport path using a lifting / lowering device, in a return path parallel to the transport direction, offset either above or below the forward path. In a further variant, the return transport of the workpiece carriers involves reversing the forward and return paths in an approximately horizontal plane relative to the respective conveyor level of the workpiece carriers.

[0049] The device variants presented here can be very efficiently parallelized in the respective process stations by processing several (e.g., two to five or approximately eight) of the modules or their precursors in parallel on the workpiece carrier, even when the workpiece carriers are transported serially from one process station to the next. Processing on the workpiece carriers, securely clamping the modules or their precursors onto the workpiece carrier between process stations, and coding the workpiece carriers for traceability can lead to more precise module manufacturing compared to the state of the art and a comparatively higher output of modules per unit of time due to the reduced number of defective parts.

[0050] In one version of the assembly line, the outbound path of the central transport track carries the numerous workpiece carriers either above or below the return path. This allows for a very space-saving arrangement of the central transport track. A largely horizontal arrangement of the outbound and return paths is also possible, but requires more floor space for the central transport track.

[0051] In one variant of the assembly line, one or more lifting devices are provided which are designed to vertically remove and reset one or more workpiece carriers from the central transport route by lifting or lowering these workpiece carriers in the z-direction, controlled by the slide, of the respective lifting devices.

[0052] In one variant of the assembly line, the central transport section on the upstream side to the stacking station includes a further lifting device which is designed to lift one or more workpiece carriers from the central transport section in the receiving area and place them on the carriage.

[0053] In one variant of the assembly line, each first workpiece carrier includes a top surface on which one or more clamps are arranged and designed to clamp stacks of electrodes located on the top surface of the workpiece carrier during transport between the process stations.

[0054] In one variant, each clamp includes a clamping jaw which is designed to bear weight on the electrode stack in a first position and to release a storage space for the electrode stack on the workpiece carrier in a second position.

[0055] In one variant, each clamp comprises a spring device designed to force the clamping jaw into the first position on the electrode stack, and a pressing point designed to receive a force input from an actuator in a process station, the applied force being directed against the spring device and causing the clamping jaw to release the storage space.

[0056] In one variant of the stacking station, each lifting device is designed to lift the respective workpiece carrier from the carriage for stacking.

[0057] The device variants described above also relate to process aspects and vice versa. Brief description of the characters

[0058] Further features, properties, advantages, and suitability of the devices and procedures can be found in the following description in conjunction with the drawings. Possible modifications will also become clear to a person skilled in the art based on the following description, which refers to the accompanying drawings. The figures schematically illustrate the devices and the process sequence discussed here. Individual aspects are explained in connection with the device, from which the process or individual steps of the process can also be directly derived.

[0059] This shows: Fig. 1. An assembly line for the production of modules or pre-modules in a schematic side view; Fig. 2 a section of an electrode stack in a schematic side sectional view; Fig. 3a a first workpiece carrier in a first orientation of the support in a schematic side sectional view; Fig. 3b the first workpiece carrier in a second orientation of the support in a schematic side sectional view; Fig. 4 a second workpiece carrier in a schematic side sectional view; and Fig. 5 a third workpiece carrier in a schematic side sectional view; Detailed description of variants of the devices and procedures

[0060] Fig. Figure 1 schematically illustrates an assembly line 100 for the production of modules or module precursors. Here, assembly line 100 is explained using fuel cells or battery cells containing layered material with or without fluid as examples.

[0061] The assembly line has a transport section 10 in which the first, second, and third workpiece carriers 20, 24, 28 circulate in their respective process stations 12, 14, 16 along rails 10a. Modules or pre-modules in the form of electrode stacks 30a, 30b are conveyed along the transport section 10. For this purpose, the workpiece carriers 20, 24, 28 each have an electric drive to circulate on / along the rail 10a in the respective process stations 12, 14, 16. Each workpiece carrier has a support 22 with a structure specifically designed for the tasks in the respective process station 12, 14, 16.

[0062] Each of the first workpiece carriers 20 is supplied with at least one first electrode stack 30a, one second electrode stack 30b, and a cover 32 in a first process station 12. The two electrode stacks 30a and 30b are identically constructed and, in the illustrated variant of a lithium iron phosphate battery, comprise at least several anode foil layers 32, several cathode foil layers 34, and several separator foil layers 36 (see figure). Fig. 2) Other lithium-ion batteries use different cathode materials such as lithium cobalt oxide (LiCoO2) or lithium nickel manganese cobalt oxide (NMC). Sodium is used as the cathode material in other variants. The cover 32 has a rectangular shape that fits a housing 34 described below and has contacts that are connected to terminals of the electrode stacks 30a, 30b. These contacts are connected via corresponding insulated leads in the cover 32 to external positive (+) and negative (-) terminals. In the first process station 12, the two electrode stacks 30a, 30b and the cover 32 are assembled to mechanically and electrically connect the first and second terminals (+, -) of the two electrode stacks 30a, 30b to the respective contacts of the cover 32.

[0063] In the first process station 12, at a first position 28a, the first electrode stack 30a, then at a second position 28b the cover 32, and then at a third position 28c the second electrode stack 30b are successively fed to a support 22 of the first workpiece carrier 20, picked up by the support 22 and fixed as a package 34. This first workpiece carrier 20 circulates in the first process station 12.

[0064] In the detailed views of the Fig. 3a and Fig. 3b of the first workpiece carrier 20 is equipped with clamps 25 for fixing the package 34 on the support 22, which can, for example, be spring-loaded or motor-operated and press the package 34 against the support 22 (see Fig. 3a). Furthermore, the support 22 is to be aligned on the first workpiece carrier 20, for example by pivoting the support 22 against the base of the workpiece carrier 20, so that at least through openings 22a or recesses 22b of the support 22 areas of a top and areas of a bottom of the package 34 or areas of the housing 38 are accessible for machining or inspection (see Fig. 3b).

[0065] The package 34, fixed to the support 22 of the first workpiece carrier 20, must be aligned relative to a gripper 22c of a second workpiece carrier 24 located in a second process station 12, for example by uprighting or pivoting. Such a second workpiece carrier 24 is shown in the detailed views of the Fig. 3a, Fig. 3b illustrates this.

[0066] In the illustrated version, the workpiece carrier 20 has several clamps 25 arranged on its transverse edges to clamp and secure the package 34, consisting of the two electrode stacks 30a, 30b and the cover 32, which is located on the support 22 of the workpiece carrier, during transport. Each clamp 25 has a clamping jaw to clamp the package 34 firmly in a first position and to release the package 34 from the workpiece carrier in a second position.

[0067] The package 34, fixed on the support 22 of the first workpiece carrier 20, is fed to a measuring device 40. During this measuring device, the position and orientation of the package 34, or of the two electrode stacks 30a, 30b and the cover 32 on the support 22 of the workpiece carrier 20, are determined and signaled to a control unit (ECU) of the transport line 10.

[0068] The package 34, fixed on the support 22 of the first workpiece carrier 20, is fed to a trimming unit 42. In one variant shown here, depending on the exact position and orientation of the two electrode stacks 30a, 30b and the cover 32 on the support 22 of the workpiece carrier 20, the first and second connecting tabs of the electrode stacks 30a, 30b and the contacts of the cover 32 are trimmed by means of two lasers 42a, 42b directed at the side edges of the two electrode stacks 30a, 30b and the cover 32. For this purpose, the two laser beams are positioned and moved by means of control data from the ECU, which also takes into account the stored position and orientation of the two electrode stacks 30a, 30b and the cover 32.

[0069] Subsequently or simultaneously, the package 34 is fed to a connector 46. Here, the first and second connecting tabs of the electrode stacks 30a, 30b, as well as the respective contacts of the cover 32, are mechanically and electrically connected to one another. In one variant shown here, depending on the exact position and orientation of the two electrode stacks 30a, 30b and the cover 32 on the support 22 of the workpiece carrier 20, the first and second connecting tabs of the electrode stacks 30a, 30b, as well as the contacts of the cover 32, are welded together by means of two lasers 46a, 46b directed at the edge regions of the two electrode stacks 30a, 30b and the cover 32. For this purpose, the two laser beams are positioned and moved using control data from the ECU, which also takes into account the stored position and orientation of the two electrode stacks 30a, 30b and the cover 32 on the support 22 of the workpiece carrier 20.

[0070] The package 34 is then transferred to one of the second workpiece carriers 24 in the second process station 12 48 (See Fig. 4) This second workpiece carrier 24 circulates with its support 22 facing downwards along the rail 10a in the second process station 14. The second workpiece carriers 24 have two pairs of grippers 27 to take over the packages 34 from the first workpiece carrier 22. The second workpiece carriers 24 serve to feed the package 34 to an inspection station 50 in the second process station 12, which follows the first process station 12. Alternatively, the inspection 50 can also take place in the first process station 12. This inspection 50 serves to inspect the stacked, trimmed, and joined / welded package 34 for properties and manufacturing details of the previous process steps. For this purpose, the package is examined for precise manufacturing using imaging by means of 2D or 3D computed tomography (CT) or radiography using X-rays for quality analysis.The internal structures of the electrode stacks are displayed, for example, showing unevenness, inclusions, air pockets, etc., as well as their connections and the connection of the cover to the housing. The results are signaled to the control unit (ECU) for storage, referencing the identifiable features of the respective second workpiece carrier 24.

[0071] If package 34 is recognized as OK up to this point, it is fed to an isolation station 52. Should package 34 be recognized as defective, it is rejected from the second process station. In the variant illustrated here, package 34 is wrapped with a plastic film around the package 34, which is located on the support of the second workpiece carrier 24 and held by the grippers 27.

[0072] The package 34, wrapped in a plastic film and thus electrically insulated, is then transferred to one of the third workpiece carriers 28 in the third process station 14 58. For this purpose, each of the third workpiece carriers 28 is configured to receive a housing on a support 22 of the third workpiece carrier 28 in the third process station 16, which follows the second process station 14. This housing is fed to the third workpiece carrier 28 externally and fixed on the support 22 of the third workpiece carrier 28 by means of laterally displaceable grippers 29 from both transverse sides of the housing 38 (see Fig. 5).

[0073] More precisely, in the present variant, the insulated package 34 is inserted from one of the second workpiece carriers 24 to an enclosure 58 into an insertion opening 38a of the housing 38 on the support 22 of the third workpiece carrier 28, so that the cover 32 covers the insertion opening 38a of the housing 38.

[0074] The housing 38 with the cover 32 is then fed into a sealing device 62. Here, the cover 32 is connected to the insertion opening 38a of the housing 38 in such a way that the cover 32 seals the insertion opening 38a in a fluid-tight manner.

[0075] The sealed housing 38 containing the package 34 is then subjected to inspection. During this process, the package 34 inside the housing 38 is X-rayed or computed tomography scanned. One or more images are acquired from one or more sides of the housing 38 and signaled to the control unit (ECU) of the transport line 10 for evaluation, with reference to the identifiable features of the respective second workpiece carrier 24.

[0076] Finally, the housing 38 with the lid 32 and the package 34 contained therein is subjected to a leak test. For this purpose, the housing 38 with the lid 32 is tested for gas tightness. This result is also signaled to the control ECU of the transport line 10 with reference to the identifiable characteristics of the respective second workpiece carrier 24.

[0077] In one variant of the assembly line, a stacking station is provided upstream of the first process station 12 and is configured to stack individual anode foil layers A, individual cathode foil layers K, and individual separating foil layers T to form an electrode stack ES on the first workpiece carrier 20. A lamination station downstream of the stacking station is provided and configured to treat a workpiece carrier coming from the stacking station with the electrode stack under pressure and / or heat so that the anode, cathode, and / or separating foil layers form a bond on the workpiece carrier's support.

[0078] The workpiece carriers 20, 24, 28 are equipped with uniquely identifiable features that are detected optically, tactilely, or wirelessly (ultrasound, infrared, (electro-)magnetically, for example, NFC) by corresponding sensors on the transport track 10. The sensors signal the features to the control unit (ECU) of the transport track 10 when the workpiece carriers 20, 24, 28 pass the corresponding sensors along the transport track 10.

[0079] The control ECU of the transport line 10 is provided and set up to process the detected features of the workpiece carriers (20, 24, 28) together with the data on the position and orientation of the electrode stack on the support of the workpiece carrier, and / or the image acquisition and / or the result of the gas tightness in the control of the transport line.

[0080] The control unit (ECU) of transport line 10 includes a data storage unit to store identifiable features (QR codes, numerical codes, barcodes, and / or similar codes) on workpiece carriers 20, 24, and 28 for tracking the modules and their precursors, along with recorded process data such as the location and orientation of the modules or their precursors. The identification of each first, second, or third workpiece carrier 20, 24, and 28 takes place at the entrance of each process station 12, 14, and 16, and the process data is recorded at the respective process point.

[0081] A process for manufacturing modules or precursors of layered material-containing fuel or battery cells comprises the following steps: - Providing a transport route 10 to convey first, second and third workpiece carriers 20, 24, 28 through process stations 12, 14, 16 along the transport route 10; wherein feeding a first electrode stack 30a, a second electrode stack 30b, and a cover 32 with its associated positive + and negative - poles and respective contacts to one of the first workpiece carriers 20; - Picking up the two electrode stacks 30a, 30b and the cover 32 on a support 22 of the first workpiece carrier 20 and fixing them as a package 34; - Feeding the fixed package 34 to a measuring device 40 in order to measure the position and orientation of the package 34 on the support 22 of the workpiece carrier 20 and to signal this to a control ECU of the transport route 10; - Feeding the fixed package 34 to a trimmer 42 to trim the first and second connection tabs of the electrode stacks 30a, 30b and the contacts of the cover 32; - Feeding the cut-to-size package 34 to a connector 46 in order to mechanically and electrically connect the first and second terminals of the electrode stacks 30a, 30b and the respective contacts of the cover 32 to each other; and - Transfer 48 of the package 34 to one of the second workpiece carriers 24 in the second process station 12; wherein - Feeding the transferred package 34 into the second process station 12 to an inspection station 50 to inspect the package 34 for properties and manufacturing details; - Feeding the inspected package 34 to an insulator 52 in order to electrically insulate the package 34 at least partially; - Transfer 58 of the package 34 to one of the third workpiece carriers 28 in the third process station 14; wherein-- transfer the package 34 to one of the third workpiece carriers 28 in the third process station 14 58; wherein - Placing a housing 38 on a support 22 of the third workpiece carrier; - Feeding the insulated package 34 into an enclosure 50 and into an insertion opening of the housing 38, so that the cover 32 covers the insertion opening of the housing 38; and - Feeding the housing 38 with the cover 32 to a closing device 62 in order to connect the cover 32 to the insertion opening of the housing 38 in such a way that the cover closes the insertion opening; - Feeding the housing 38 with the package 34 to a checker to X-ray the package 34 and the housing 38 for image acquisition and to signal the image acquisition to the control of the transport line 10 for evaluation; and - Feeding the housing 38 with the lid 32 and the package 34 to a leak test in order to check the housing 38 with the lid 32 for gas tightness and to signal the result to the control of the transport route.

[0082] The previously described variants of the assembly line, their design and operational aspects, as well as the variants of the procedure, serve only to better understand the structure, function, and properties; they do not limit the disclosure to the exemplary embodiments. Some of the figures are schematic. In some cases, essential properties and effects are shown significantly enlarged to clarify the functions, operating principles, technical designs, and features. Each function, principle, technical design, and feature disclosed in the figures or in the text may be combined with all claims, features in the text, and in the other figures.Other functionalities, principles, technical configurations, and features contained in or arising from this disclosure may be freely and arbitrarily combined, such that all conceivable combinations of the described procedure are included. This also encompasses combinations between all individual embodiments in the text, i.e., in every section of the description, in the claims, and also combinations between different variants in the text, in the claims, and in the figures. The claims do not limit the disclosure and thus the possible combinations of all the features shown. All disclosed features are explicitly disclosed here, both individually and in combination with all other features.

Claims

[1] An assembly line for the production of modules or precursors of layered fuel or battery cells comprising - a transport route (10), designed and equipped to convey first, second and third workpiece carriers (20, 24, 28) through process stations (12, 14, 16) along the transport route (10); wherein - each of the first workpiece carriers (20) is provided and set up to be used in a first process station (12) at least -- a first electrode stack (30a) supplied to the first workpiece carrier (20), -- a second electrode stack (30b) supplied to the first workpiece carrier (20), as well as -- a cover (32) supplied to the first workpiece carrier (20) to the two electrode stacks (30a, 30b) with associated positive (+) and negative (-) poles and respective contacts, provided and designed to mechanically and electrically contact a respective first and a respective second connecting lug of the two electrode stacks (30a, 30b), to receive it on a support (22) of the workpiece carrier (20) and to fix it as a package (34); -- the fixed package (34) is provided and equipped to measure the position and orientation of the electrode stack on the support (22) of the workpiece carrier (20) and to signal this to a control (ECU) of the transport route (10); -- to feed the package (34) to a trimming (42), provided and equipped to trim the first and second connecting tabs of the electrode stacks (30a, 30b) and the contacts of the cover (32); -- to feed the package (34) to a connector (46), designed and configured to mechanically and electrically connect the first and second terminals of the electrode stacks (30a, 30b) and the respective contacts of the cover (32) to each other; and -- to transfer the package (34) to one of the second workpiece carriers (24) in the second process station (12) (48); wherein - each of the second workpiece carriers (24) is provided and set up for use in the second process station (12) following the first process station (12) -- to subject the package (34) to an inspection (50), designed and equipped to inspect the package (34) for properties and manufacturing details; -- to feed the inspected package (34) to an insulator (52), provided and equipped to electrically insulate the package (34) at least in certain areas; -- to transfer the package (34) to one of the third workpiece carriers (28) in the third process station (14) (58); wherein - Each of the third workpiece carriers (28) is designed and equipped to receive a housing on a support (22) of the third workpiece carrier in the third process station (16) following the second process station (14). -- to insert the insulated package (34) from one of the second workpiece carriers (24) to an enclosure (50) into an insertion opening of the housing (38) on a support (22) of the third workpiece carrier (28), so that the cover (32) covers the insertion opening of the housing (38); and -- the housing (38) with the cover (32) to a closing (62), provided and arranged to connect the cover (32) to the insertion opening of the housing (38) in such a way that the cover closes the insertion opening; -- the housing (38) with the package (34) is provided and equipped to perform an inspection, to X-ray the package (34) and the housing (38) for image acquisition and to signal the image acquisition to the control of the transport line (10) for evaluation; and -- the housing (38) with the lid (32) and the package (34) is provided and equipped to perform a leak test, to test the housing (38) with the lid (32) for gas tightness and to signal the result to the control of the transport route. [2] The assembly line according to claim 1, wherein the package (34) or the housing (38) fixed on the support (22) is to be aligned on the workpiece carrier, for example by pivoting, tilting or rotating the support (22), such that at least through openings or recesses (27) of the support (22) areas of a top and areas of a bottom of the package (34) or areas of the housing (38) are accessible for machining or inspection. [3] The assembly line according to claim 1 or 2, wherein the package (34) fixed on the support (22) is to be aligned relative to a gripper of a second workpiece carrier located in a second process station (12), for example by erecting. [4] The assembly line according to one of the preceding claims comprises - a stacking point on the upstream side of the first process station, provided and equipped for stacking individual anode foil layers and individual cathode foil layers and / or individual separator foil layers to form an electrode stack on a first workpiece carrier; and / or - a lamination station downstream of the stacking station is provided and equipped to treat a workpiece carrier coming from the stacking station with the electrode stack with pressure and / or heat so that the anode, cathode and / or separating film layers form a bond. [5] The assembly line according to one of the preceding claims, wherein - the workpiece carriers (20, 24, 28) are provided with uniquely identifiable features which are to be detected by corresponding sensors on the transport track (10) and signaled to the control unit (ECU) of the transport track (10); and / or wherein - the control unit (ECU) of the transport section (10) is provided and equipped to process the detected features of the workpiece carriers (20, 24, 28) together with the data on the position and orientation of the electrode stack on the support of the workpiece carrier, and / or the image acquisition and / or the result of the gas tightness in the control unit of the transport section. [6] The assembly line according to one of the preceding claims, wherein - in the control unit (ECU) of the transport line (10) a data storage unit is provided to store identifiable features QR, number, bar and / or similar codes, together with recorded process data such as location and orientation of the modules or their precursors, for the purpose of tracing the modules and their precursors on the workpiece carriers (20, 24, 28); and / or wherein the identification of the individual first, second or third workpiece carriers (20, 24, 28) takes place at the entrance of each process station (12, 14, 16), and / or the recording of the process data takes place at the respective process location. [7] The assembly line according to any one of claims 4 to 6, wherein - the stacking station is designed and equipped to form individual anode foil layers and individual cathode foil layers and / or individual separating foil layers from first, second and / or third continuous layer material and to dispense as a sequence of individual anode foil layers, cathode foil layers and / or separating foil layers alternately to form the electrode stack. [8] The assembly line according to any one of claims 1 to 7, wherein - the support of the workpiece carrier can be swivelled out of a plane of the workpiece carrier by at least approximately 70-110°, for example 90°; and / or - the workpiece carrier support has openings and / or recesses to provide access to the stack of electrodes located on the workpiece carrier support; and / or - the workpiece carrier has one or more clamps, arranged and configured to clamp the stack of electrodes located on the support of the workpiece carrier during transport, each clamp having a clamping jaw, provided and configured to clamp the stack of electrodes in a first position and to release the stack of electrodes on the workpiece carrier in a second position. [9] A method for manufacturing modules or precursors of layered fuel or battery cells, comprising the steps: - Providing a transport route (10) to convey first, second and third workpiece carriers (20, 24, 28) through process stations (12, 14, 16) along the transport route (10); wherein a first electrode stack (30a), a second electrode stack (30b), and a cover (32) with associated positive (+) and negative (-) poles and respective contacts to one of the first workpiece carriers (20); - Picking up the two electrode stacks (30a, 30b) and the lid (32) on a support (22) of the first workpiece carrier (20) and fixing them as a package (34); - Feeding the fixed package (34) to a measuring device (40) to measure the position and orientation of the package (34) on the support (22) of the workpiece carrier (20) and to signal this to a control unit (ECU) of the transport route (10); - Feeding the fixed package (34) to a trimming machine (42) to trim the first and second terminal tabs of the electrode stacks (30a, 30b) and the contacts of the cover (32); - Feeding the cut-to-size package (34) to a connector (46) to mechanically and electrically connect the first and second terminals of the electrode stacks (30a, 30b) and the respective contacts of the cover (32) to each other; and - Transferring (48) the package (34) to one of the second workpiece carriers (24) in the second process station (12); wherein - Feeding the transferred package (34) into the second process station (12) for inspection (50) to inspect the package (34) for properties and manufacturing details; - Feeding the inspected package (34) to an insulator (52) in order to electrically insulate the package (34) at least in certain areas; - Transferring (58) the package (34) to one of the third workpiece carriers (28) in the third process station (14); wherein-- transferring the package (34) to one of the third workpiece carriers (28) in the third process station (14) (58); wherein - Receiving a housing (38) onto a support (22) of the third workpiece carrier; - Feeding the insulated package (34) into an enclosure (50) and into an insertion opening of the housing (38), so that the cover (32) covers the insertion opening of the housing (38); and - Feeding the housing (38) with the cover (32) to a closing mechanism (62) in order to connect the cover (32) to the insertion opening of the housing (38) in such a way that the cover closes the insertion opening; - Feeding the housing (38) with the package (34) to a checker to X-ray the package (34) and the housing (38) for image acquisition and to signal the image acquisition to the transport line control (10) for evaluation; and - Feeding the housing (38) with the lid (32) and the package (34) to a leak test in order to check the housing (38) with the lid (32) for gas tightness and to signal the result to the control of the transport route.

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