Multi-Gripper Robot Arm for Cylindrical Battery Module Assembly
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Solution Overview
Problem
The manual assembly of cylindrical battery cells into battery modules is cumbersome and difficult to automate, leading to increased manufacturing costs and reduced production efficiency, as well as safety concerns due to potential erroneous assembly.
Innovation Solution
A manufacturing apparatus equipped with a robot arm featuring multiple grippers and a disk with a rotary driving unit, which includes a dented groove to prevent cell damage, an elastic fixing frame to absorb impact, and an erroneous assembling sensor to detect incorrect assembly, facilitating efficient and safe assembly of battery modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual assembly is used to accommodate cylindrical battery cells in module housing, then assembly flexibility is maintained, but labor intensity increases and automation becomes difficult
Solution Approach 1:
The module housing is divided into upper case and lower case that can be separately assembled, and the battery cells are accommodated in a segmented manner using multiple grippers that can independently hold and position individual cells or groups of cells
Solution Approach 2:
A robot arm serves as an intermediary device between the battery cell supply and the module housing, enabling automated transfer and precise positioning of cylindrical battery cells into the housing without direct manual handling
2Productivity
If multiple industrial robots are used for various manufacturing processes, then production efficiency increases, but equipment costs increase sharply
Solution Approach 1:
A single robot arm is designed to perform multiple manufacturing functions including holding battery cells with the first gripper, holding the upper case with the second gripper, holding the lower case with the third gripper, and coordinating with the rotary driving unit to complete the entire assembly process, replacing what would traditionally require multiple specialized robots
3Object-affected harmful factors
If dented groove is added to first tong unit, then cell damage is prevented, but device complexity increases
Solution Approach 1:
The first tong unit incorporates a dented groove at the specific location where it contacts the cylindrical battery cell, creating a localized structural feature that prevents the tong from pressing directly on the cell body, thereby preventing damage without requiring complex modifications to the entire tong unit structure
4Manufacturing precision
If erroneous assembling sensor is implemented, then assembly accuracy improves, but manufacturing cost increases
Solution Approach 1:
An erroneous assembling sensor is integrated into the assembly system to detect and provide feedback on incorrect battery cell orientations or positions, enabling real-time monitoring and correction of assembly errors to ensure high manufacturing precision
Data Source
AI summary
Discussed is a manufacturing apparatus including a robot arm, which may increase production efficiency and greatly reduce the size of manufacturing equipment. The manufacturing apparatus includes a robot arm to manufacture a battery module that includes a plurality of cylindrical battery cells and a module housing having an upper case and a lower case configured to accommodate the plurality of cylindrical battery cells. The robot arm includes a first gripper configured to hold or release the plurality of cylindrical battery cells; a second gripper configured to hold or release the upper case; and a third gripper configured to hold or release the lower case.