Serial EV Battery Cell Handling and Testing System

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Solution Overview

Problem

Current pick and place systems for EV battery cells are inflexible, prone to unstable engagement, and require multiple handling operations, leading to reduced throughput and accuracy in testing and assembly, especially when dealing with different cell types and configurations.

Innovation Solution

A robotic system that uses a manipulation tool with gripping elements to engage and test EV battery cells during transit, allowing for serial pick and place operations, including electronic testing and unique ID reading, while ensuring stable engagement and flexible handling of various cell types.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If multiple EV battery cells are picked up and placed at the same time, then throughput is improved, but the system becomes inflexible when cell dimensions change and engagement becomes problematic

Engineering Contradiction:

ImprovethroughputVSAvoidflexibility

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The system segments the handling process into individual cell operations rather than bulk handling. Each cell is picked up, tested, and placed separately through a serial process, allowing the system to adapt to different cell types while maintaining throughput through automated sequencing.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The robotic system employs dynamic reconfiguration capabilities where the end effector and robot positioning can be programmatically adjusted for different cell dimensions and configurations, enabling flexibility without sacrificing automated throughput.

Inventive Principle:

Principle #15Dynamics

2Ease of operation

If vacuum systems are used to pick up EV battery cells, then engagement is achieved, but stable engagement is not provided during accelerated travel or machine stoppage

Engineering Contradiction:

ImproveengagementVSAvoidstable engagement

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The system extracts the cell from the vacuum field by using a mechanical latch or夹持 mechanism that positively secures the cell after initial vacuum contact, removing the cell from the unreliable vacuum-only engagement state during accelerated travel.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The system applies a secondary mechanical engagement mechanism that activates before vacuum failure can occur, providing a backup engagement method that prevents cell drop during acceleration or deceleration events.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Measurement precision

If multiple pick and place operations are performed between shipping container and battery module, then cell testing can be conducted, but throughput is reduced

Engineering Contradiction:

Improvefault detection accuracyVSAvoidthroughput

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The system merges the pick and place operation with the testing operation into a single integrated workflow. The cell is picked up, immediately tested while held by the end effector, and then placed, eliminating separate handling steps and reducing total cycle time while maintaining comprehensive testing.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The testing operation continues uninterrupted during the transfer process. The cell is tested while being held by the robotic end effector during movement between locations, maximizing the utilization of each handling operation and eliminating idle time.

Inventive Principle:

Principle #20Continuity of useful action

4Productivity

If later fault rejects are implemented at the end of assembly line, then assembly is completed, but cost increases when faulty modules are detected

Engineering Contradiction:

Improveassembly completionVSAvoidfault detection timing

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system performs preliminary testing on individual cells before they are assembled into the battery module. Faulty cells are identified and rejected early in the process, preventing defective modules from being assembled and eliminating costly rework or recalls later in the production line.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS20230400529A1Serial handling and testing of electrical components

Publication Date: 2023.12.14 ATS IND AUTOMATION INC

AI summary

A robotic system for manipulating an electrical component between a first location and a second location, the system comprising: a movement element for moving a manipulation tool between the first location and the second location; the manipulation tool having one or more gripping elements for engaging the electrical component by grabbing the electrical component at the first location when the manipulation tool is positioned adjacent to the electrical component; and a testing system for implementing an electronic test of the electrical component while the electrical component is engaged by the manipulation tool, the testing system implementing the electronic test before the manipulation tool releases the electrical component; wherein upon reaching the second location the manipulation tool disengages with the electrical component, thereby reversing said engaging.