Assembly line and method for manufacturing modules or precursors of modules

Abstract

An assembly line comprises a transport route for conveying first, second, and third workpiece carriers through process stations. Each first workpiece carrier is designed and equipped to receive at least one first electrode stack, a second electrode stack, and a supplied cover on a support of the workpiece carrier in a first process station and to fix them as a package. The electrode stacks and the cover with its associated positive and negative poles and respective contacts contact a first and a second connection tab of the two electrode stacks. The fixed package is fed to a measuring to measure the position and alignment of the package on the support and to signal this to a control system for the transport route. The package is fed to a trimming station to trim the first and second connection tabs of the electrode stacks and the contacts of the cover. The package is fed to a connecting station to connect the first and second connection tabs of the electrode stacks and the respective contacts of the cover to each other. The package is transferred to one of the second workpiece carriers in the second process station. Each of the second workpiece carriers feeds the package to an inspection station to inspect the package for properties and manufacturing details, feeds the inspected package to an insulation station to electrically insulate at least some areas of the package, and transfers the package to one of the third workpiece carriers in the third process station. Each of the third workpiece carriers picks up a housing on a support of the third workpiece carrier, inserts the insulated package from the second workpiece carrier into an insertion opening of the housing on a support of the third workpiece carrier so that the cover covers the insertion opening of the housing, and guides the housing with the cover to a sealing in order to connect the cover to the insertion opening of the housing in such a way that the cover closes the insertion opening, guides the housing with the package to a testing device in order to X-ray the package and the housing for image capture and to signal the image capture to the transport line control system for evaluation, and subjects the housing with the cover and the package to a leak test to check the housing with the cover for gas tightness and signals the result to the transport line control system.

Description

[0001] MB Automation GmbH & Co. KG -1 - 30A-167 913

[0002] Assembly line and method for manufacturing modules or precursors of modules

[0003] Description

[0004] Background

[0005] This invention relates to an assembly line and a method for manufacturing modules or precursors of modules, in particular of layer material and / or fuel or battery cells. Details are defined in the claims, but the description also contains relevant information on the structure and mode of operation as well as on variants of the method and the device components.

[0006] State of the art

[0007] In fuel cell or battery cell production, the machines in which the respective process steps are carried out are conventionally operated as individual machines (so-called stand-alone devices). This applies, for example, to the stacking of electrodes in a stacking machine (known as a "stacker"), 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 for welding the electrical connection tabs. Each processing station of the different production stages of the workpiece (e.g., cell stack) has its own transport system (feed, processing, removal). Data processing (recording of the workpiece to be processed, recording of relevant data of the workpiece, image inputs or measured values, e.g. for quality control, etc.) takes place in the processing station and by the processing station. For this purpose, 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 succession leads to deviations in manufacturing precision and delays in the transfer of the respective intermediate product from one machine to the next. Overall, this can result in large fluctuations in product quality.

[0008] JP 2020 138 854 A relates to a laminating device with a feed device that feeds a film body; a pallet that is transported along a transport path; the film body fed by the feed device is laminated on the pallet. A guide rail is provided along the transport path.

[0009] EP 3 424 075 Bl relates to a handling system with a rail and independent and coordinated shuttles for industrial automation with a linear motor with an electromagnetic drive. The shuttles engage with the same rail and run along it while performing their function. Each shuttle has feed means for moving along the rail with processing and control means. The system coordinates the activities of the shuttles, 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 MB Automation GmbH & Co. KG 30A-167 913 shuttles. Permanent magnets are integrated into the rail to interact with coils located on each shuttle so that the shuttles are independent of each other in their movement and in the function to be performed, allowing them to be removed from or added to the system individually. Each shuttle is connected in a wireless mode for information transmission. Sliding contacts or wireless electromagnetic induction are used for power supply. Automatic means for determining the position of each shuttle communicate continuously along the entire path of the rail with a reference reader attached to each shuttle. The system has a central control and processing unit with a central server equipped with control logic with executive programs configured to process the information received from the simultaneously active shuttles and from the sensor means. The shuttles are moved on the same track in an independent but coordinated manner, synchronously and / or asynchronously. Each shuttle has a self-propelled sliding shoe as a pusher, which is removably attached to the rail and comprises all active means for performing the feed movement along the rail. These are primary motion control and communication means. Each sliding shoe is autonomous and independent, including the coils on board, which are selectively activated for electromagnetic propulsion, as well as their control unit, sensors, and means for receiving and transmitting information. Each shuttle is connected wirelessly for power supply and data transmission. The sliding shoe has means for wireless power supply from the rail, movable coils, a logic control unit for managing the primary movement 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 for managing communication with access ports for software updates or for control diagnostics, an antenna for wireless communication, for example for updating data, tasks or positions, collision sensor means for preventing collision of shuttles, transducer means with position sensors for fixed, continuous, and absolute reference located in the rail, or absolute value encoders for micrometric position control, means for high-speed proximity communication. The rail comprises a power supply with a fixed power line to be transmitted to the moving shuttles in two alternative ways: by contact or contactless ( ) using electromagnetic induction means, in which, instead of brushes, a number of receivers are mounted on the shuttles, fixed permanent magnets for linking the magnetic flux of the linear motors of the 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 means or controlling the inclination of the means. The means form a shell for holding and positioning a photovoltaic cell for the function of the secondary drives. These are means that are removably connected to the self-propelled sliding shoe and can be detached on command from the sliding shoe or the central server. The shuttle functions as a captain or as a slave depending on the planned task or the specific coding or MB Automation GmbH & Co.KG -3 - 30A-167 913 traffic or accidents. The rail is a linear and compact, bidirectional, double-sided integrated rail and comprises an upper rail lying above a lower rail, which are integrated with each other, with lateral tilting, the lateral tilting being effected by a tilting means with a rotary motor configured to tilt a whole section of the rail, including guides, magnets, and power supply so that the shuttle engaging in the upper rail is tilted 180° to accommodate a section of the lower rail, and vice versa from bottom to top, or to perform partial rotations, for example 90°, to move onto another rail section.

[0010] Technical problem

[0011] Based on this situation, a cost-effective and robust arrangement and procedure with high processing speed is to be provided in order to be able to manufacture modules or precursors of modules, in particular fuel or battery cells containing layer material.

[0012] Proposed solution

[0013] To solve this problem, an assembly line and a method according to the independent claims are proposed. Further developments and variants are the subject of the dependent claims.

[0014] An assembly line comprises a transport path for conveying first, second, and third workpiece carriers through process stations. Each first workpiece carrier is designed and equipped to receive at least one first electrode stack, a second electrode stack, and a cover on a support of the workpiece carrier in a first process station and to fix them as a package. The electrode stacks and the cover with its associated positive and negative poles and respective contacts contact a first and a second connection tab of the two electrode stacks. The fixed package is fed to a measuring to measure the position and alignment of the package on the support and to signal this to a control system for the transport route. The package is fed to a trimming station to trim the first and second connection tabs of the electrode stacks and the contacts of the cover. The package is fed to a connecting station to connect the first and second connection tabs of the electrode stacks and the respective contacts of the cover to each other. The package is transferred to one of the second workpiece carriers in the second process station. Each of the second workpiece carriers feeds the package to an inspection station to inspect the package for properties and manufacturing details, feeds the inspected package to an insulation station to electrically insulate the package at least in some areas, and transfers the package to one of the third workpiece carriers in the third process station. Each of the third workpiece carriers picks up a housing on a support of the third workpiece carrier, inserts the insulated package from the second workpiece carrier into an insertion opening of the housing on a support of the third workpiece carrier so that the cover covers the insertion opening of the housing, and guides the housing with the cover to a sealing in order to connect the cover to the insertion opening of the housing in such a way that the MB Automation GmbH & Co.KG -4 - 30A-167 913 cover closes the insertion opening, guides the housing with the package to a testing device in order to X-ray the package and the housing for image capture and to signal the image capture to the transport line control system for evaluation, and subjects the housing with the cover and the package to a leak test in order to check the housing with the cover for gas tightness and signals the result to the transport line control system.

[0015] Such an assembly line for manufacturing modules or preliminary stages of fuel or battery cells containing layer material comprises a transport line designed and equipped to convey workpiece carriers between process stations.

[0016] In this assembly line, a transport line is provided and designed to convey first, second, and third workpiece carriers through process stations along the transport line.

[0017] In a variant of the assembly line, a data memory is provided in the control system of the transport route in order to store identifiable features assigned to the workpiece carriers in the form of QR®, numerical, bar and / or similar codes together with recorded process data, such as position data, measurement data, location and orientation of the modules or their preliminary stages on the workpiece carriers.

[0018] Each of the first workpiece carriers is provided in this assembly line and designed to receive, in a first process station, at least one first electrode stack supplied to the first workpiece carrier, a second electrode stack supplied to the first workpiece carrier, and a cover with positive and negative poles assigned to it and supplied to the first workpiece carrier for the two electrode stacks and respective contacts, is provided and designed to mechanically and electrically contact a respective first and a respective second connection tab of the two electrode stacks, to pick up the fixed package on a support of the workpiece carrier and to fix it as a package.

[0019] Each of the first workpiece carriers is provided in this assembly line and is designed to feed the fixed package to a measuring, which is provided and designed to measure a position and an alignment of the electrode stack on the support of the workpiece carrier and to signal this to a control system for the transport route.

[0020] Each of the first workpiece carriers is provided in this assembly line and is designed to feed the package to a trimming, which is designed to trim the first and second connection tabs of the electrode stacks and the contacts of the cover. MB Automation GmbH & Co.KG -5 - 30A-167 913

[0021] Each of the first workpiece carriers in this assembly line is designed and set up to feed the package to a connecting designed and set up to connect the first and second connection tabs of the electrode stacks and the respective contacts of the cover to each other mechanically and electrically.

[0022] In a variant, the trimming and connecting of the first and second connecting tabs of the two electrode stacks and the contacts of the cover is carried out by means of a laser. This can be different lasers. In a variant, the trimming and connecting are carried out with the same laser, which is operated with different operating parameters. In the latter case, in a variant, the first workpiece carrier is not moved relative to the transport path.

[0023] The first workpiece carriers are provided in this assembly line and are designed to transfer the package to one of the second workpiece carriers in the second process station. In a variant, the package is transferred in such a way that it is clamped firmly between two or more fingers on the second workpiece carrier and hangs freely.

[0024] Each of the second workpiece carriers is provided in this assembly line and designed to feed the package to the second process station following the first process station for inspection, and is designed to inspect the package for properties and manufacturing details. This inspection (recording and evaluating the position data, measurement data, location, and alignment of the modules or their precursors on the workpiece carrier) is performed in a variant of the assembly line using tactile and / or imaging methods. The result of the inspection is communicated to the transport route control system and stored by the control system together with the identifiable feature assigned to the respective workpiece carrier.

[0025] Each of the second workpiece carriers in this assembly line is designed and equipped to feed the inspected package to an insulator, which is designed and equipped to electrically insulate at least part of the package. In a variant of this insulation, the package held by the second workpiece carrier is inserted into a plastic bag (polyethylene, polypropylene, or similar) or the plastic bag is placed over the package held by the second workpiece carrier (from below). Alternatively, the package held by the second workpiece carrier is wrapped with a plastic film web. In one alternative, the support with the package is rotated relative to a feed of the plastic film web about an axis of rotation of the support. In a further alternative, the plastic film web is looped around the fixed package on the support.

[0026] Each of the second workpiece carriers is provided in this assembly line and is designed to transfer the package to one of the third workpiece carriers in the third process station. In a MB Automation GmbH & Co. KG -6 - 30A-167 913 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.

[0027] 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 following the second process station.

[0028] Each of the third workpiece carriers is provided in this assembly line and is designed to receive the package consisting of the two electrode stacks and the cover from one of the second workpiece carriers and to place it in an enclosure in an insertion opening of the housing on a support of the third workpiece carrier so that the cover covers the insertion opening of the housing.

[0029] Each of the third workpiece carriers is provided in this assembly line and is designed to feed the housing with the cover to a sealing, which is designed to connect the cover to the insertion opening of the housing in such a way that the cover seals the insertion opening in a gas-tight and / or liquid-tight manner. This can be achieved, for example, by (laser) welding, folding, flanging or the like.

[0030] Each of the third workpiece carriers in this assembly line is designed and set up to feed the housing with the package to a test, and is designed and set up to X-ray the package and the housing for image capture and to signal the image capture to the transport line control system for evaluation.

[0031] Each of the third workpiece carriers is provided in this assembly line and is designed and set up to feed the housing with the cover and the package to a leak test, to check the housing with the cover for gas tightness, and to signal the result to the transport line control system.

[0032] In a variant, the assembly line comprises a stacking station upstream of the first process station, which is designed and set up 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.

[0033] In a variant, a laminating station is provided downstream of the stacking station and is designed to treat a workpiece carrier coming from the stacking station with the electrode stack using pressure and / or heat so that the anode, cathode, and / or separating foil layers form a composite. MB Automation GmbH & Co.KG -7 - 30A-167 913

[0034] In a variant of the assembly line, the workpiece carriers are provided with clearly identifiable features which are to be detected by corresponding sensors on the transport route and signaled to the control system of the transport route.

[0035] In a variant of the assembly line, the transport route is controlled and set up to process the recorded characteristics of the workpiece carriers together with the data on the position and alignment of the electrode stack on the support of the workpiece carrier and / or the image feed and / or the result of the gas tightness in the transport route control system.

[0036] In a variant of the assembly line, the individual workpiece carriers are identified at the entrance to each process station and / or the process data is recorded at the respective process point.

[0037] In a variant, the location and orientation of the housing on the support of the third workpiece carrier is measured, for example by means of imaging or tactilely, and its serial number is determined, for example by means of imaging, for the purpose of enclosing it in the insertion opening of the housing on the support of the third workpiece carrier.

[0038] In a variant, a serial number of the housing is stored in a control system for the transport route. When the package is fed from the second workpiece carrier into the housing on the support of the third workpiece carrier, the data relating to the package is added to the data of the third workpiece carrier. This ensures that the individual product and its production process can always be traced.

[0039] In a variant of the assembly line, at least the support of the first workpiece carrier can be swiveled out of a plane of the workpiece carrier by at least approximately 70-110°, for example 90°. This facilitates imaging or trimming and / or connecting / welding or other processing of the package or the housing with or without the package inside in a variant.

[0040] In a variant of the assembly line, the support surface of the workpiece carrier has openings and / or recesses to provide access to the electrode stack located on the support surface of the workpiece carrier.

[0041] In a variant of the assembly line, the first, second, or third workpiece carriers have one or more clamps arranged and designed to clamp the electrode stack, housing, etc. located on the support of the workpiece carrier, each clamp having a clamping jaw designed and arranged to clamp the electrode stack in a first position and in a second position to release the electrode stack on the workpiece carrier. MB Automation GmbH & Co. KG -8 - 30A-167 913

[0042] Such an assembly line with its workpiece carriers allows the respective process stations to be operated in an interactive and automated manner. The workpiece carriers with their superstructures 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 area requirements) than previous solutions.

[0043] Previously, each processing station for the workpieces (electrode stacks) had its own transport system (feed, processing, removal). Data processing (recording of the workpiece to be processed, recording of the relevant data of the workpiece, image captures or measured values, e.g. for quality control, etc.) was carried out in and by the processing station. For this purpose, each processing station has its own process computer capacity and communicates with the control system to ensure orderly transport to the next processing station.

[0044] The solution presented here is based on an assembly line with a continuous linear workpiece transport route, along which individual process stations are lined up, and which has a route control system, whereby the control system coordinates the individual process stations as subsystems of the workpiece transport route. This allows for optimized interlinking of the process steps performed at 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 with the necessary transfer of workpieces from one process station to the next.

[0045] At the end of the transport route, in a variant of the assembly line, the workpiece carriers are unloaded for return transport. Before this, the electrode packages that are to be further processed or examined are removed from their housings, for example by means of a pick & place process. The empty workpiece carriers are then returned to the start of the transport route on their way back. In a variant, all workpiece carriers are provided with clearly identifiable features. Corresponding sensors on the transport route enable comprehensive traceability of the modules and their preliminary stages for storing the respective data. The identifiable features include QR codes, numbers, barcodes, and / or similar codes. The individual workpiece carriers can be identified with the workpiece they are carrying at the entrance to each process station or within each process station.

[0046] Preparatory measures required for a new process step, e.g., clamping the electrode stack, measuring the electrode stack, unclamping the electrode stack, can be eliminated at least in MB Automation GmbH & Co. KG -9 - 30A-167 913 part. The solution presented here allows for an increased overall processing rate of the workpieces.

[0047] The multifunctional workpiece carriers work together with the workpiece transport route as a master, so that the individual process stations do not work independently of each other and do not need to be connected first; instead, an integrated network of process stations is realized by the workpiece carriers with the workpiece transport route.

[0048] The workpiece transport route is linear; rotary tables for the workpiece carriers circulating the workpieces are not required. This also facilitates parallelization with the required traceability and easier documentation of the individual process steps, including the coding of the workpiece carriers.

[0049] 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 following process steps up to packaging with an insulating material can be carried out on the same workpiece carrier.

[0050] In a variant of the assembly line, a first cutting or punching station is set up to form the electrode stack, to cut a first continuous layer material and, as a result of separated anode foil layers, to deliver them, for example, to the stacking point; A second cutting or punching station is set up to cut a second continuous layer material and deliver it as individual cathode foil layers, for example, to the stacking point. Similarly, a third cutting or punching station is set up to cut a third continuous layer material and deliver it as individual separating film layers, for example, to the stacking station.

[0051] The electrode stacks wrapped in insulating material can be inserted directly into the housing mounted on the third workpiece carrier.

[0052] The internal structures of the electrode stacks and their connections, as well as the connection between the cover and the housing, are visualized by means of 2D or 3D computer tomography (CT) or X-ray radiation for quality analysis. These tests, as well as leak tests of the welded housings using helium, for example, can be carried out before the final process steps and tests are performed in the dry room. This allows for a more compact dry room.

[0053] The workpiece carriers are returned downstream of each process station in a variant of the assembly line, e.g., to remove the electrode stacks if the respective module or its preliminary MB Automation GmbH & Co. KG -10 - 30A-167 913 stages are found to be out of order. In another variant of the assembly line, the workpiece carriers are returned at the end of the transport route by means of a respective lifting / lowering device in a return route parallel to the transport direction and offset above or below the outward route of the transport route. In another variant, the return transport of the workpiece carriers includes implementing or diverting the outward and return paths in an approximately horizontal plane to the respective conveyor plane of the workpiece carriers.

[0054] The device variants presented here can be parallelized very efficiently in the respective process stations by processing several (e.g., two to five or approx, eight) of the modules or their precursors on the workpiece carrier in parallel, even if the serial workpiece carriers are transported from one process station to the next. The processing on the workpiece carriers and the secure clamping of the modules or their precursors on the workpiece carriers between the process stations, as well as the coding of the workpiece carriers for traceability, can lead to more precise manufacturing of the modules compared to the state of the art and a comparatively higher output of modules per unit of time due to the lower number of nonconforming parts.

[0055] In a variant of the assembly line, the outward journey of the central transport route above or below the return journey conveys the large number of workpiece carriers. This allows for a very space-saving arrangement of the central transport route. A largely horizontal arrangement of the outward and return journeys is also possible, but requires more installation space for the central transport route.

[0056] In a variant of the assembly line, one or more lifting devices are provided which are designed to remove one or more workpiece carriers from the central transport route vertically and to reset them by lifting the respective workpiece carriers from the slide in the z direction or lowering them in the z direction in a controlled manner.

[0057] In a variant of the assembly line, the central transport path upstream of the stacking station comprises a further lifting device which is designed to lift one or more workpiece carriers from the central transport path in the pick-up area and place them on the slide.

[0058] In a variant of the assembly line, each first workpiece carrier comprises an upper side on which one or more clamps are arranged and designed to clamp electrode stacks located on the upper side of the workpiece carrier during transport between the process stations. MB Automation GmbH & Co. KG -11 - 30A-167 913

[0059] In a variant, each clamp comprises a clamping jaw that is designed to bear on the electrode stack in a first position and, in a second position, to release a storage space for the electrode stack on the workpiece carrier.

[0060] In a variant, each clamp comprises a spring device designed to press the clamping jaw into the first position on the electrode stack, and a pressing point which is designed to receive a force applied by 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.

[0061] In a variant of the stacking station, each lifting device is designed to lift the respective workpiece carrier from the slide for stacking.

[0062] The device variants described above also relate to process aspects and vice versa.

[0063] Brief description of the figures

[0064] Further features, characteristics, advantages, and practicalities of the devices and methods are described below in conjunction with the drawings. Possible modifications will also be apparent to a person skilled in the art from the following description, which refers to the accompanying drawings. The figures schematically show the devices discussed here and the sequence of the method. Individual aspects are explained in connection with the device, from which the process or individual steps of the process can also be directly derived.

[0065] Shown here:

[0066] Fig. 1 shows an assembly line for manufacturing modules or precursors of modules in a schematic side view;

[0067] Fig. 2 shows a section of an electrode stack in a schematic side sectional view;

[0068] Fig. 3a shows a first workpiece carrier in a first orientation of the support in a schematic side sectional view;

[0069] Fig. 3b shows the first workpiece carrier in a second orientation of the support in a schematic side sectional view;

[0070] Fig. 4 shows a second workpiece carrier in a schematic side sectional view; and

[0071] Fig. 5 a third workpiece carrier in a schematic side sectional view. MB Automation GmbH & Co. KG -12 - 30A-167 913

[0072] Detailed description of variants of the devices and methods

[0073] Fig. 1 schematically illustrates an assembly line 100 for manufacturing modules or precursors of modules. Here, the assembly line 100 is explained by way of example using fuel cells or battery cells that contain layered material with or without fluid.

[0074] The assembly line has a transport section 10 in which first, second, and third workpiece carriers 20, 24, 28 circulate in respective process stations 12, 14, 16 guided by rails 10a. Modules or preliminary stages of modules in the form of electrode stacks 30a, 30b are conveyed along the transport route 10. For this purpose, the workpiece carriers 20, 24, 28 each have an electric drive for circulating in the respective process stations 12, 14, 16 on / at the rail 10a. Each of the workpiece carriers has a support 22 with a structure that is specifically designed for the tasks in the respective process station 12, 14, 16.

[0075] Each of the first workpiece carriers 20 is supplied with at least one first electrode stack 30a, a second electrode stack 30b, and a cover 32 in a first process station 12. The two electrode stacks 30a, 30b are identical in design and, in the illustrated version 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 Fig. 2). Other lithium-ion batteries use different cathode materials such as lithium cobalt oxide (LiCoO2) or lithium nickel manganese cobalt oxide (NMC). In other variants, sodium is used as the cathode material. The cover 32 has a rectangular shape that fits a housing 34 explained below and contacts that are connected to terminals of the electrode stacks 30a, 30b. These contacts are connected to external positive (+) and negative (-) poles via corresponding insulated lines in the cover 32. In the first process station 12, the two electrode stacks 30a, 30b and the cover 32 are assembled in order to mechanically and electrically connect a respective first and a respective second connection tab +, - of the two electrode stacks 30a, 30b to the respective contacts of the cover 32.

[0076] For this purpose, in the first process station 12, first the first electrode stack 30a is mounted at a first location 28a, then the cover 32 at a second location 28b, and then the second electrode stack 30b at a third location 28c 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.

[0077] In the detailed views of Figs. 3a and 3b of the first workpiece carrier 20, the latter is equipped with clamps 25 for fixing the package 34 on the support 22, which, for example, can press the package 34 against the support 22 by means of spring force or motor action (see Fig. 3a). In addition, the support 22 must be aligned on the first workpiece carrier 20, MB Automation GmbH & Co. KG -13 - 30A-167 913 for example by pivoting the support 22 against the base of the workpiece carrier 20, so that at least areas of an upper side and areas of a lower side of the package 34 or areas of the housing 38 are accessible for machining or inspection through openings 22a or recesses 22b in the support 22, areas of an upper side and areas of a lower side of the package 34 or areas of the housing 38 are accessible for machining or inspection (see Fig. 3b).

[0078] The package 34 fixed on the support 22 of the first workpiece carrier 20 is to be aligned relative to a gripper 22c of a second workpiece carrier 24 located in a second process station 12, for example by erecting or swivelling. Such a second workpiece carrier 24 is illustrated in the detailed views of Figs. 3a and 3b.

[0079] In the variant shown, the workpiece carrier 20 has several clamps 25 arranged on its transverse edges in order to clamp and fix the package 34 located on the support 22 of the workpiece carrier from the two electrode stacks 30a, 30b and the cover 32 during transport. For this purpose, each clamp 25 has a clamping jaw for clamping the package 34 in a first position and releasing the package 34 on the workpiece carrier in a second position.

[0080] The package 34 fixed on the support 22 of the first workpiece carrier 20 is fed to a measuring 40. During this measurement, the position and alignment of package 34 or the two electrode stacks 30a, 30b and the cover 32 on support 22 of workpiece carrier 20 are determined and signaled to a control ECU of transport section 10.

[0081] The package 34 fixed on the support 22 of the first workpiece carrier 20 is fed to a trimming 42. In a variant shown here, depending on the , the exact position and alignment of the two electrode stacks 30a, 30b and the cover 32 on the support 22 of the workpiece carrier 20 are determined by means of two lasers 42a, 42b directed at the side edges of the two electrode stacks 30a, 30b and the cover 32. 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 take into account the stored position and alignment of the two electrode stacks 30a, 30b and the cover 32.

[0082] Subsequently or simultaneously, the package 34 is fed to a connecting 46. Here, the first and second connecting tabs of the electrode stacks 30a, 30b and the respective contacts of the cover 32 are mechanically and electrically connected to each other. In a variant shown here, depending on the exact position and alignment of the two electrode stacks 30a, 30b and the cover 32 on the support 22 of the workpiece carrier 20, the first and second connection tabs of the electrode stacks 30a, 30b and the contacts of the cover 32 are welded together by means of two lasers 46a, 46b directed at the edge areas of the two MB Automation GmbH & Co. KG -14 - 30A-167 913 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 take into account the stored position and alignment of the two electrode stacks 30a, 30b and the cover 32 on the support 22 of the workpiece carrier 20.

[0083] 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 the support 22 facing downwards on the rail 10a in the second process station 14. The second workpiece carriers 24 have two pairs of grippers 27 to take the packages 34 from the first workpiece carrier 22. The second workpiece carriers 24 serve to feed the package 34 to an inspection 50 in the second process station 12 following 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 connected / welded package 34 for properties and manufacturing details from the previous process steps. For this purpose, the package is examined for precise manufacturing by means of imaging using 2D or 3D computer tomography (CT) or X-ray transmission for quality analysis. The internal structures of the electrode stacks are examined, for example, for unevenness, air inclusions or the like, and their connections and the connection of the cover to the housing are displayed. The results are signaled to the ECU control system for storage with reference to the identifiable features of the respective second workpiece carrier 24.

[0084] If the package 34 is recognized as OK up to this point, it is fed to an insulator 52. If the package 34 is recognized as not OK, the package 34 is ejected from the second process station. In the variant illustrated here, the package 34 is wrapped with a plastic film web around the package 34 located on the support of the second workpiece carrier 24 and held by the grippers 27.

[0085] The package 34, which is wrapped in the plastic film and thus electrically insulated, is then transferred to one of the third workpiece carriers 28 in the third process station 14. For this purpose, each of the third workpiece carriers 28 is designed to accommodate a housing on a support 22 of the third workpiece carrier 28 in the third process station 16 following the second process station 14. This housing is fed to the third workpiece carrier 28 from outside and fixed on both transverse sides of the housing 38 on the support 22 of the third workpiece carrier 28 by means of laterally displaceable grippers 29 (see Fig. 5).

[0086] More precisely, in the present variant, the insulated package 34 is introduced from one of the second workpiece carriers 24 into an enclosure 58 in an insertion opening 38a of the MB Automation GmbH & Co. KG -15 - 30A-167 913 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.

[0087] The housing 38 with the cover 32 is then fed to a sealing 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.

[0088] The sealed housing 38 with the package 34 is then fed to a testing station. The package 34 is X-rayed or scanned by means of computer tomography in the housing 38 for image acquisition. One or more images are captured from one or more sides of the housing 38 and signaled to the ECU of the transport line 10 for evaluation with reference to the identifiable features of the respective second workpiece carrier 24.

[0089] Finally, the housing 38 with the cover 32 and the package 34 located therein are subjected to a leak test. For this purpose, the housing 38 with the cover 32 is checked for gas tightness. This result is also signaled to the ECU of the transport line 10 with reference to the identifiable features of the respective second workpiece carrier 24.

[0090] In a variant of the assembly line, a stacking station is provided upstream of the first process station 12 and is designed to stack individual anode foil layers A and individual cathode foil layers K and individual separating foil layers T to form an electrode stack ES on the first workpiece carrier 20. A laminating station downstream of the stacking station is provided and designed to treat a workpiece carrier coming from the stacking station with the electrode stack using pressure and / or heat so that the anode, cathode, and / or separating foil layers form a composite on the support of the workpiece carrier.

[0091] The workpiece carriers 20, 24, 28 are provided with uniquely identifiable features which can be detected optically, tactilely or wirelessly (ultrasound, infrared, (electro-)magnetic, for example NFC) by corresponding sensors on the transport route 10. The sensors signal the features to the ECU control of the transport route 10 when the workpiece carriers 20, 24, 28 pass the corresponding sensors along the transport route 10.

[0092] The ECU of the transport line 10 is designed and set up to process the detected characteristics 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 feed and / or the result of the gas tightness in the control system of the transport line. MB Automation GmbH & Co. KG -16 - 30A-167 913

[0093] A data memory is provided in the ECU of the transport section 10 in order to store identifiable features provided on the modules and their precursors on the workpiece carriers 20, 24, 28 together with recorded process data, such as the location and orientation of the modules or their precursors. The individual first, second, or third workpiece carriers 20, 24, 28 are identified at the entrance to each process station 12, 14, 16, and the process data is recorded at the respective process point.

[0094] A method for manufacturing modules or precursors of fuel or battery cells containing sheet material comprises the steps of

[0095] - providing a transport path 10 for conveying first, second and third workpiece carriers 20, 24, 28 through process stations 12, 14, 16 along the transport path 10; wherein feeding 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;

[0096] - 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;

[0097] - feeding the fixed package 34 to a measuring 40 in order to measure a position and an alignment of the package 34 on the support 22 of the workpiece carrier 20 and to signal this to a control ECU of the transport path 10;

[0098] - feeding the fixed package 34 to a trimming 42 in order to trim the first and second connection tabs of the electrode stacks 30a, 30b and the contacts of the cover 32;

[0099] - feeding the trimmed package 34 to a connecting 46 in order to mechanically and electrically connect the first and second connection tabs of the electrode stacks 30a, 30b and the respective contacts of the cover 32 to one another; and

[0100] - transferring 48 the package 34 to one of the second workpiece carriers 24 in the second process station 12;

[0101] - feeding the transferred package 34 in the second process station 12 to an inspection 50 in order to inspect the package 34 for properties and manufacturing details;

[0102] - feeding the inspected package 34 to an isolating 52 in order to electrically isolate the package 34 at least in some areas;

[0103] - transferring 58 the package 34 to one of the third workpiece carriers 28 in the third process station 14;

[0104] - receiving a housing 38 on a support 22 of the third workpiece carrier;

[0105] - feeding the insulated package 34 into an insertion opening of the housing 38 so that the cover 32 covers the insertion opening of the housing 38; and

[0106] - feeding the housing 38 with the cover 32 to a sealing 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; MB Automation GmbH & Co. KG -17 - 30A-167 913

[0107] - supplying the housing 38 with the package 34 to a test in order to illuminate the package 34 and the housing 38 for image capture and to signal the captured image to the control of the transport path 10 for evaluation; and

[0108] - subjecting the housing 38 with the cover 32 and the package 34 to a leak test in order to check the housing 38 with the cover 32 for gas tightness and signal the result to the control system of the transport line.

[0109] The variants of the assembly line described above, their structural and operational aspects, and the variants of the method are only intended to provide a better understanding of the structure, function, and properties; they do not limit the disclosure to the embodiments. The figures are partly schematic. Essential properties and effects are shown in some cases in greatly enlarged form in order to illustrate the functions, operating principles, technical designs, and features. Any mode of operation, principle, technical design, or feature disclosed in the figures or in the text may be freely combined with all claims, any feature in the text and in the other figures, other modes of operation, principles, technical designs, and features contained in this disclosure or resulting therefrom, so that all conceivable combinations of the described method can be assigned. This also includes combinations between all individual embodiments in the text, i.e., in each 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 also do not limit the disclosure and thus the possible combinations of all the features disclosed. All disclosed features are also explicitly disclosed here individually and in combination with all other features.

Claims

MB Automation GmbH & Co. KG -18 - 30A-167 913Claims1. An assembly line for manufacturing modules or precursors of fuel or battery cells containing layer material, comprising- a transport path (10) provided and designed to convey first, second, and third workpiece carriers (20, 24, 28) through process stations (12, 14, 16) along the transport path (10); wherein- each of the first workpiece carriers (20) is provided and designed to receive, 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), and- a cover (32) supplied to the first workpiece carrier (20) to the two electrode stacks (30a, 30b) with positive (+) and negative (-) and respective contacts, and designed and arranged to mechanically and electrically contact a respective first and a respective second connection tab of the two electrode stacks (30a, 30b), to be accommodated on a support (22) of the workpiece carrier (20) and fixed as a package (34);- feeding the fixed package (34) to a measuring (40) designed and set up to measure the position and alignment of the electrode stack on the support (22) of the workpiece carrier (20) and to signal this to a control unit (ECU) of the transport line (10);- feeding the package (34) to a trimming (42) designed and set up to trim the first and second connection tabs of the electrode stacks (30a, 30b) and the contacts of the cover (32);- feeding the package (34) to a connecting (46) designed and arranged to connect the first and second connecting tabs of the electrode stacks (30a, 30b) and the respective contacts of the cover (32) to each other mechanically and electrically; and- transferring (48) the package (34) to one of the second workpiece carriers (24) in the second process station (12); wherein- each of the second workpiece carriers (24) is provided and designed to transfer the package (34) to the second process station (12) following the first process station (12)- to feed the package (34) to an inspection (50), which is provided and designed to inspect the package (34) for properties and manufacturing details;- to feed the inspected package (34) to an isolating (52) provided and designed to electrically isolate the package (34) at least in some areas;- transferring (58) the package (34) to one of the third workpiece carriers (28) in the third process station (14); whereinMB Automation GmbH & Co. KG -19 - 30A-167 913- each of the third workpiece carriers (28) is designed and set up 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);- inserting the insulated package (34) from one of the second workpiece carriers (24) into an enclosing (50) in 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- feeding the housing (38) with the cover (32) to a sealing (62) provided and designed 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) to be subjected to a test, provided and designed to illuminate the package (34) and the housing (38) for image capture and to signal the image capture to the control of the transport path (10) for evaluation; and- the housing (38) with the cover (32) and the package (34) is provided for and designed to be subjected to a leak test, in order to check the housing (38) with the cover (32) for gas tightness and to signal the result to the control system of the transport line.

2. The assembly line according to claim 1, in which the package (34) fixed on the support (22) or the housing (38) is to be aligned on the workpiece carrier, for example by swivelling, tilting or rotating the support (22), such that at least areas of an upper side and areas of a lower side of the package (34) or areas of the housing (38) are accessible for processing or inspection through openings or recesses (27) in the support (22).

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 previous claims comprises- a stacking station upstream of the first process station, provided and designed to stack individual anode foil layers and individual cathode foil layers and / or individual separating foil layers to form an electrode stack on a first workpiece carrier; and / or- a laminating station downstream of the stacking station, designed and set up to treat a workpiece carrier coming from the stacking station with the electrode stack with e pressure and / or heat so that the anode, cathode, and / or separator foil layers form a composite.

5. The assembly line according to one of the previous claims, wherein- the workpiece carriers (20, 24, 28) are provided with clearly identifiable features which areMB Automation GmbH & Co. KG -20 - 30A-167 913 to be detected by corresponding sensors on the transport route (10) and signaled to the control unit (ECU) of the transport route (10); and / or wherein- the control unit (ECU) of the transport line (10) is provided and designed to transmit 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 input and / or the result of the gas tightness in the control of the transport line.

6. The assembly line according to one of the previous claims, wherein- a data memory is provided in the control (ECU) of the transport line (10) in order to store, for the traceability of the modules and their precursors on the workpiece carriers (20, 24, 28) together with recorded process data, such as the location and orientation of the modules or their precursors; 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 one of claims 2 to 6, wherein- the stacking station is provided and designed 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, as a result of separated anode foil layers, cathode film layers and / or separating film layers alternately to form the electrode stack.

8. The assembly line according to any 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 support of the workpiece carrier has openings and / or recesses to provide access to the electrode stack located on the support of the workpiece carrier; and / or- the workpiece carrier has one or more clamps arranged and designed to clamp the electrode stack located on the support of the workpiece carrier during transport, each clamp having a clamping jaw, which is provided in a first position and designed to clamp the electrode stack in place, and in a second position to release the electrode stack on the workpiece carrier, and in a second position to release the electrode stack on the workpiece carrier.

9. A method for manufacturing modules or precursors of fuel cells or battery cells containing layer material, comprising the steps:- providing a transport path (10) for conveying first, second, and third workpiece carriers (20, 24, 28) through process stations (12, 14, 16) along the transport path (10); whereinMB Automation GmbH & Co. KG -21 - 30A-167 913 feeding 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 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 (40) in order to measure a position and an alignment 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 trimming (42) in order to trim the first and second connection tabs of the electrode stacks (30a, 30b) and the contacts of the cover (32);- feeding the trimmed package (34) to a connecting (46) in order to mechanically and electrically connect the first and second connection tabs of the electrode stacks (30a, 30b) and the respective contacts of the cover (32) to one another; and- transferring (48) the package (34) to one of the second workpiece carriers (24) in the second process station (12);- feeding the transferred package (34) in the second process station (12) to an inspection (50) to inspect the package (34) for properties and manufacturing details;- feeding the inspected package (34) to an insulating (52) in order to electrically insulate the package (34) at least in some areas;- transferring (58) the package (34) to one of the third workpiece carriers (28) in the third process station (14);- the package (34) is transferred (58) to one of the third workpiece carriers (28) in the third process station (14);- picking up a housing (38) on a support (22) of the third workpiece carrier;- feeding the insulated package (34) to an enclosing (50) in 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 sealing (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;- supplying the housing (38) with the package (34) to a testing device in order to scan the package (34) and the housing (38) for image capture and to signal the image capture to the control of the transport path (10) for evaluation; and- feeding the housing (38) with the cover (32) and the package (34) to a leak test in order to check the housing (38) with the cover (32) for gas tightness and signaling the result to the control system of the transport path.

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