Battery Pack Pre-Welding Positioning With Vision-Guided Hole Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Inaccurate identification of welding positioning holes in battery packs leads to low yield and efficiency in subsequent welding processes.
Innovation Solution
A pre-welding positioning system comprising a frame body, a controller, a three-axis mechanism, a vision acquisition system, and a fixing component, which accurately determines and adjusts the position of the battery pack using product information and distance deviation values to ensure precise fixation before welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual alignment and tack welding are used for positioning, then device complexity is reduced, but manufacturing precision and productivity deteriorate due to time-consuming operations and inconsistency
Solution Approach 1:
The patent replaces manual mechanical alignment and tack welding operations with an automated optical measurement system. The system uses a scanner to capture point cloud data of the first and second parts, automatically calculates positioning parameters, and guides the welding process, thereby improving positioning precision while the mechanical complexity is managed through automated control algorithms
Solution Approach 2:
The patent creates a digital copy of the physical parts through point cloud scanning. The scanner generates accurate three-dimensional point cloud data that represents the actual geometry and position of the parts, which is then used for automated positioning calculations, eliminating the need for physical trial-and-error alignment
2Productivity
If manual alignment and tack welding are used for positioning, then device complexity is reduced, but productivity deteriorates due to lengthy positioning processes
Solution Approach 1:
The patent replaces time-consuming manual alignment and tack welding operations with an automated optical measurement and calculation system. The scanner rapidly captures point cloud data, and the control device automatically computes positioning parameters, dramatically reducing positioning time and improving productivity while managing system complexity through automated control
Solution Approach 2:
The patent performs preliminary scanning and measurement of the parts before the actual welding process. By capturing point cloud data and calculating positioning parameters in advance, the system prepares all necessary information beforehand, allowing the welding operation to proceed efficiently without interruptions for manual measurement or adjustment
3Manufacturing precision
If point cloud data scanning is performed before welding, then manufacturing precision improves, but production time increases due to additional scanning steps
Solution Approach 1:
The patent implements a continuous workflow where the scanner continuously or rapidly captures point cloud data of the parts, and the control device continuously processes this data to calculate positioning parameters. This continuous action eliminates idle time between scanning and positioning, maintaining high precision while minimizing production cycle time
Solution Approach 2:
The patent performs the scanning and positioning calculation as a preliminary step that is quickly executed before welding. By completing the time-consuming measurement and computation work beforehand, the actual welding process can proceed without interruptions, and the overall time loss is minimized because the preliminary data collection is automated and efficient
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present disclosure discloses a pre-welding positioning system and method, the pre-welding positioning system including: a frame body, a controller, a three-axis mechanism arranged on the frame body, and a vision acquisition system and a fixing component arranged on the three-axis mechanism, where the controller is configured to control the three-axis mechanism to move to a designated position based on product information of a battery pack to be welded; the vision acquisition system is configured to acquire, at the designated position, an image of a positioning component of the battery pack, in response to the three-axis mechanism reaching the designated position; and determine a distance deviation value between the positioning component and a preset reference point based on the acquired detection image; and the controller is further configured to control the three-axis mechanism to drive the fixing component to the positioning component based on the distance deviation value so as to fix the battery pack to the frame body by the fixing component.