Automated Battery Testing and Sorting via Industrial Robot
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Solution Overview
Problem
Current battery testing and sorting systems are inflexible, labor-intensive, and lack automation, leading to high labor costs, low efficiency, and inconsistent results, as they require manual operation and are not adaptable to various battery shapes or capable of parallel feeding, testing, and sorting.
Innovation Solution
A system utilizing an industrial robot with a manipulator and controller, equipped with a gripper, that picks, tests, and sorts batteries within a compact and flexible configuration, allowing for automated material handling, testing, and sorting, reducing human error and improving accuracy and productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual operation is used for battery testing and sorting, then the system is simple and flexible, but labor cost is high and efficiency is low
Solution Approach 1:
The robot arm serves multiple functions: picking batteries from the holding section, transporting them to the testing section, and moving tested batteries to sorting sections. This multi-functionality reduces the need for separate dedicated machines for each operation, achieving automation while controlling system complexity
Solution Approach 2:
The robot arm acts as an intermediary between the battery holding section, testing section, and sorting sections. It mediates the material handling process, enabling automated operation without requiring complex direct coupling between all system components
2Productivity
If sequential processing is used for feeding, testing and sorting, then the system is simple, but productivity is low
Solution Approach 1:
The robot arm continuously picks batteries from the holding section and transports them to the testing section without interruption. The testing section continuously tests batteries as they arrive, and the sorting section continuously sorts tested batteries. This continuous operation eliminates idle time between operations, significantly improving productivity
Solution Approach 2:
Batteries are pre-positioned in the holding section at locations that the robot arm can easily access. The robot arm is pre-programmed with the sequence of operations and positions, allowing it to perform picking and transporting actions efficiently without delays for positioning or reconfiguration
3Adaptability or versatility
If fixed configuration is used for testing and sorting system, then the system is stable, but adaptability to various installation spaces is poor
Solution Approach 1:
The robot arm provides dynamic positioning capability, allowing the system to adapt to different installation spaces and battery positions. The arm can move to various coordinates within its working range, enabling the system to accommodate different spatial configurations while maintaining stable automated operation through programmable control
Solution Approach 2:
The system is divided into separate functional modules: battery holding section, robot arm, testing section, and sorting sections. Each module can be independently positioned and configured within the installation space, allowing flexibility in system layout while maintaining the stability of individual functional components
Data Source
AI summary
A system includes a robot, comprising a manipulator and a controller, with a gripper mounted on the manipulator, for picking the battery for testing and sorting, a battery holding section for receiving batteries for testing and sorting at predetermined locations in the battery holding section, and a testing section disposed within the working range of the robot, for testing an electrical condition of the battery for testing and sorting, whereby the controller controls the manipulator and the gripper to first-pick the battery for testing and sorting at the predetermined location from the battery holding section and place it to contact the testing section for testing, the testing section tests the battery and sends to the controller a signal indicating the electrical condition of the tested battery, and the controller controls the manipulator and the gripper to second-pick the battery contacting the testing section and sort it according to the signal.