Battery Module Welding Layout with Parallel Conveyors
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Solution Overview
Problem
The existing welding systems for battery module assemblies in electric vehicles are costly to establish and suffer from reduced operational efficiency due to the need for multiple expensive oscillators and the requirement for all welding facilities to stop when one is broken down or needs maintenance.
Innovation Solution
A welding system with a main conveyor and parallel auxiliary conveyors, loading-unloading modules, clamping jigs, and multiple welding robots that can perform welding processes independently, allowing for continuous operation even if one conveyor or robot is abnormal, and includes features like a suction module for fume removal and a saltwater container for fire extinguishing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple welding facilities are disposed in series along a conveyor, then welding coverage is improved, but the cost increases due to multiple expensive oscillators
Solution Approach 1:
Multiple welding robots are merged into a single integrated system that shares one oscillator. The oscillator is positioned to serve multiple welding robots simultaneously, eliminating the need for separate oscillators at each welding station. This reduces the total number of expensive oscillator components while maintaining comprehensive welding coverage across multiple battery pack assemblies.
Solution Approach 2:
The single oscillator is designed with universal functionality to serve multiple welding robots. It can generate ultrasonic vibrations that are distributed to different welding positions through the shared conveyor system, allowing one oscillator to perform the function of multiple separate oscillators would have performed individually.
2Adaptability or versatility
If welding facilities are disposed in series along a conveyor, then welding coverage is improved, but the operation rate decreases when one facility needs maintenance
Solution Approach 1:
The welding system is segmented into multiple independent welding robots that operate on parallel auxiliary conveyors. Each welding robot can function independently, and the system can continue operating with reduced capacity if one robot or conveyor requires maintenance. The main conveyor continues to supply battery pack assemblies while selective welding operations proceed on available auxiliary conveyors.
Solution Approach 2:
The system dynamically adapts its operation based on the status of individual welding robots and auxiliary conveyors. When maintenance is needed, the system reconfigures to utilize only the functional components, maintaining operational flexibility and avoiding complete system shutdown. This dynamic reconfiguration preserves reliability while allowing necessary maintenance activities.
3Area of stationary object
If battery pack assemblies are conveyed in series, then space utilization is improved, but the cycle time increases due to sequential processing
Solution Approach 1:
The system transitions from purely sequential one-dimensional processing to a multi-dimensional parallel processing architecture. Multiple auxiliary conveyors run parallel to the main conveyor, creating a two-dimensional processing layout that allows simultaneous welding operations at different positions. This spatial arrangement reduces cycle time by enabling concurrent processing while maintaining efficient space utilization through compact vertical and horizontal integration.
Solution Approach 2:
The parallel auxiliary conveyors enable continuous welding operations without interruption. While the main conveyor continuously supplies battery pack assemblies, multiple welding robots simultaneously perform welding at different stations. This continuous parallel action eliminates idle time and reduces overall cycle time compared to sequential processing, where each welding operation must wait for the previous one to complete.
Data Source
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AI summary
Disclosed are a welding system and a welding method using the same. The welding system may include: a main conveyor configured to convey a battery palette on which a battery module assembly is mounted; at least two auxiliary conveyors disposed in parallel with the main conveyor; a loading-unloading module configured to transfer the battery palette, which is conveyed along the main conveyor, to the auxiliary conveyor and transfer the battery palette, which is completely subjected to a preset welding process, from the auxiliary conveyor to the main conveyor; clamping jigs on which the battery palettes are seated by the loading-unloading module so that the preset welding process is performed on the battery module assemblies on the auxiliary conveyors; and at least two welding robots configured to weld the battery module assemblies seated on the at least two auxiliary conveyors.