Battery Gap Filler Applicator With Shared Pumps and Full-Case Coverage
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Solution Overview
Problem
Existing gap filler applicator systems for electric vehicle battery assemblies require large installation areas and excessive investment costs due to the need for multiple robots and separate resin/hardener pumps, limiting productivity and maintainability.
Innovation Solution
A battery gap filler applicator using a plurality of orthogonal robots with shared resin and hardener pumps, equipped with booster pumps and adjustable application units, allows for efficient gap filler application across the entire lower case surface while reducing installation space and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If four multi-joint robots are placed at left and right sides of a lower case to apply gap filler, then the filling time is shortened, but the installation area becomes huge and investment cost is excessively required
Solution Approach 1:
The patent combines multiple robot functions into a single orthogonal robot system. Instead of using four separate multi-joint robots, one orthogonal robot with multiple degrees of freedom performs gap filler application at multiple locations simultaneously or sequentially, reducing the installation area while maintaining filling efficiency
Solution Approach 2:
The orthogonal robot is designed with universal functionality to perform gap filler application at multiple positions on the lower case. The robot can rotate and position its application head at different locations, replacing multiple specialized robots with one multi-functional unit, thus reducing space requirements
2Reliability
If four multi-joint robots are used with individual resin and hardener pumps for each robot, then the filling operation is comprehensive, but the investment cost is excessively required
Solution Approach 1:
The patent merges the resin pump and hardener pump resources into a shared configuration. Instead of having individual pumps for each robot, one or two pumps serve multiple orthogonal robots through a centralized supply system, reducing the number of pumps required and lowering investment cost while maintaining reliable material supply to all application points
Solution Approach 2:
The resin and hardener pumps are designed with universal supply capability to serve multiple orthogonal robots. The pumps can distribute materials to different robots as needed, providing comprehensive filling operation support without requiring dedicated pumps for each robot, thus reducing system complexity and cost
3Area of stationary object
If one robot is used to apply gap filler, then the installation area is reduced, but it is impossible to apply gap filler in an entire region of the lower case
Solution Approach 1:
The orthogonal robot incorporates dynamic movement capabilities including rotation and positioning mechanisms that enable it to reach different regions of the lower case. The robot can dynamically adjust its position and orientation to cover the entire application area, ensuring complete gap filler coverage while maintaining a compact installation footprint
Solution Approach 2:
The orthogonal robot utilizes multi-axis movement and rotation capabilities to access areas that would be unreachable with a single-position robot. By operating in multiple dimensions through rotation and repositioning, the robot achieves comprehensive coverage of the lower case surface without requiring multiple stationary robots distributed across large areas
Data Source
AI summary
Provided is a battery gap filler applicator applying a gap filler to a lower case of an electric vehicle battery system assembly (BSA), including: a plurality of orthogonal robots disposed at an upper portion of a conveyor device on which a lower case is seated; spaced apart from each other by a predetermined distance; moving at the upper portion of the conveyor device; and applying a resin and a hardener onto the lower case. The battery gap filler applicator may further include a booster pump supplying the resin and the hardener to the plurality of orthogonal robots; and a resin pump and a hardener pump filling the resin and the hardener, respectively to the booster pump.