EV Battery Tray TIM Dispensing With Vision-Based Nozzle Offset
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Solution Overview
Problem
The application of thermal interface material (TIM) in electric vehicle battery packs is challenging due to the complexity of applying 2-component liquid TIM, which has a short shelf-life and requires precise application to meet thermal performance targets, especially considering the abrasive nature of silicone-based TIMs and the need for rapid application in manufacturing.
Innovation Solution
A system combining a material dispensing system with robotics and a vision system to accurately dispense a mixture of TIM components on a tray in a defined pattern, utilizing heated conduits to control material temperature and imaging devices to ensure proper application and inspection, thereby improving manufacturing efficiency and quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If 2-component liquid TIM is used for thermal management, then thermal performance is improved, but shelf-life is reduced and application complexity increases
Solution Approach 1:
The TIM is divided into two separate components (resin and hardener) stored in different reservoirs, which are only mixed at the point of application. This segmentation allows each component to maintain its stability and shelf-life independently while still achieving the desired thermal performance when combined.
Solution Approach 2:
The system prepares the TIM components in advance by storing them separately in a stable state, and only performs the mixing action immediately before application. This preliminary separation preserves shelf-life while enabling the chemical reaction needed for thermal management performance.
2Temperature
If silicone-based 2-component TIM is used, then thermal performance is improved, but abrasiveness increases and handling difficulty increases
Solution Approach 1:
The system introduces a controlled mixing mechanism that acts as an intermediary between the two TIM components and the application surface. The mixing occurs in a controlled environment within the dispensing system, preventing premature curing and reducing abrasiveness during handling and application.
Solution Approach 2:
The system controls the physical and chemical parameters of the TIM by maintaining separate storage conditions for each component and only initiating the chemical reaction at the point of application. This parameter control reduces the abrasive properties during handling while preserving thermal performance.
3Manufacturing precision
If precise TIM application is performed manually, then thermal performance targets are met, but manufacturing time increases and productivity decreases
Solution Approach 1:
The system replaces manual mechanical application with an automated robotic dispensing system that uses computer-controlled mechanisms to apply the TIM. This substitution maintains precise application quality while dramatically increasing manufacturing speed and productivity.
Solution Approach 2:
The dispensing system is designed to automatically mix and dispense the TIM without requiring manual intervention for each application. The system self-regulates the mixing ratio, dispensing amount, and application pattern, enabling high-speed automated manufacturing while maintaining precision.
4Productivity
If rapid TIM application is performed to meet manufacturing demands, then productivity is improved, but application precision may deteriorate
Solution Approach 1:
The system incorporates feedback mechanisms that monitor the dispensing process in real-time and automatically adjust parameters to maintain application precision. Sensors detect variations in dispensing rate, material flow, and application pattern, and the control system makes real-time corrections to ensure consistent quality at high speeds.
Solution Approach 2:
The dispensing system is designed with dynamic capabilities that allow it to adapt its operation in real-time. The robotic arm, mixing mechanism, and dispensing rate are all dynamically controlled to maintain precision during rapid application, adjusting parameters based on position, material properties, and process conditions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enables precise and efficient application of TIM, enhancing thermal management in electric vehicle battery packs by ensuring consistent patterns and quality, adaptable to different vehicle types and improving manufacturing efficiency.
Implementation Method 1
a first heated conduit and a second heated conduit... configured to provide the first material to the end-effector tool at a first desired temperature
Implementation Method 2
an end-effector tool having a mixing vessel and a nozzle fluidly coupled to the mixing vessel... dispense a third material on the tray in a defined pattern, where the third material is a mixture of the first material and the second material
Implementation Method 3
2-component liquid TIM is made of resin and hardener materials that are cured via a catalyst reaction
Data Source
AI summary
A system for providing a thermal interface material on a tray for an electric vehicle battery includes a material dispensing system (MDS) and a vision system. The MDS includes a set of pumps, a robotic dispensing system (RDS), and a controller. The set of pumps includes a first pump to house a first material and a second pump to house a second material different from the first material. The RDS is fluidly coupled to the set of pumps and dispenses a third material on the tray in a defined pattern, where the third material is a mixture of the first and second materials. The vision system is configured to capture a first set of images. The controller is configured to determine a nozzle offset of the RDS based on the first set of images and control a position of the RDS based on the nozzle offset.