Guided Material and Socket Assembly for Mixed-Line Pack Production
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Solution Overview
Problem
The lithium battery industry faces challenges in achieving accurate assembly due to the complexity of mixed-line production in pack assembly lines, which often results in manual assembly errors.
Innovation Solution
A material assembly method and system that includes a control device, a material cabinet, a socket selector, a host computer, and a tightening gun controller. The system automatically opens the correct cabinet door and indicates the correct socket to be taken, enabling the tightening gun controller only when the correct socket is removed, thus ensuring accurate assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual assembly is used in mixed-line production, then assembly flexibility is maintained, but assembly accuracy deteriorates due to human errors
Solution Approach 1:
The system enables operators to independently complete accurate material selection and assembly operations through automated guidance. The control device automatically identifies required materials and sockets, displays them on screens, and guides operators through the assembly process, eliminating the need for complex centralized control while ensuring high assembly accuracy
Solution Approach 2:
The patent replaces manual identification and selection mechanisms with automated visual display systems. Control devices with screens automatically show material and socket information, replacing the need for operators to manually search through catalogs or identification systems, thereby improving accuracy without significantly increasing physical system complexity
2Manufacturing precision
If automated control systems are implemented to improve assembly accuracy, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The control system is divided into independent functional modules: material cabinet control, socket selector control, display devices, and tightening gun control. Each module operates independently based on simple control signals from the host computer, reducing overall system complexity while maintaining high assembly accuracy through coordinated operation of segmented components
Solution Approach 2:
The control device serves multiple functions: it controls material cabinet doors, manages socket selector indicators, displays information on screens, and controls tightening gun activation. This multi-functional design reduces the need for separate control systems for each function, thereby improving assembly accuracy without proportionally increasing device complexity
3Manufacturing precision
If strict socket verification is implemented to improve assembly accuracy, then manufacturing precision is improved, but productivity decreases due to additional verification steps
Solution Approach 1:
The system performs preliminary identification and verification of the correct socket before the actual assembly operation. The control device pre-identifies the required socket, displays it on the socket selector screen, and guides the operator to select it in advance. This preliminary action ensures high socket picking accuracy while maintaining assembly efficiency by avoiding rework from incorrect selections
Solution Approach 2:
The system provides real-time feedback through display screens showing the correct material and socket information. The socket selector displays visual feedback to confirm the selected socket matches the required one. This immediate feedback mechanism ensures high assembly accuracy without requiring multiple verification steps, thereby maintaining productivity
Data Source
AI summary
A system includes a control device, a material cabinet, a socket selector, a host computer, and a tightening gun controller. The control device, when receiving target material picking information sent by the host computer, controls the material cabinet to open a target cabinet door according to the target material picking information to indicate taking a target material away, and controls the socket selector to perform target socket indication processing. A cabinet body corresponding to the target cabinet door includes the target material. The control device, when determining that the target socket has been taken away, enables the tightening gun controller, or when determining that the target socket has not been taken away, does not enable the tightening gun controller. The tightening gun controller, when enabled, executes assembly processing of the target material through the target socket if a tightening trigger instruction is received.