Robot-Guided Clip Setting for Battery Vent Valve Assembly
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Solution Overview
Problem
The manual assembly of vent valves in high-voltage battery systems disrupts automated production processes, requiring additional time and ergonomic considerations due to the high pressing force needed for clip insertion, which existing devices fail to address effectively.
Innovation Solution
A robot-guided setting device with a transfer unit and setting unit that includes a supply unit, setting piston, and process control system to automate the insertion of plastic clips into component pilot holes, compensating for position tolerances and ensuring precise placement using centering elements and force monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual setting of vent valve is used, then ergonomic requirements are met, but production time increases and automation is disrupted
Solution Approach 1:
The patent replaces the manual mechanical setting operation with an automated robot-guided setting device. The robot executes pre-programmed motions to position and insert the plastic clip, eliminating the need for manual intervention while maintaining ergonomic standards through automated force application.
Solution Approach 2:
The setting device is designed to automatically perform the complete setting operation without human assistance. The robot picks up the clip from the supply unit, positions it precisely, and applies the necessary insertion force autonomously, making the system self-sufficient for the vent valve assembly task.
2Productivity
If automated setting device is introduced, then production time is reduced, but device complexity increases
Solution Approach 1:
The robot-guided setting device is designed as a multi-functional unit that combines pickup, positioning, and setting operations. The same robot mechanism performs both the pickup operation from the supply unit and the subsequent setting operation, reducing the need for separate specialized devices and simplifying the overall system architecture.
Solution Approach 2:
The setting device acts as an intermediary between the robot and the plastic clip. It provides a standardized interface for force application and position control, simplifying the robot's control requirements while ensuring precise and reliable clip insertion. The setting device mediates the complex interaction between robotic motion and mechanical insertion.
3Reliability
If pressing force is increased to ensure secure insertion, then retention reliability is improved, but risk of damage to component increases
Solution Approach 1:
The robot-guided setting device performs preliminary positioning of the plastic clip before applying insertion force. The centering element pre-aligns the clip with the pilot hole, ensuring that the full insertion force is applied along the correct axis. This preliminary alignment prevents lateral forces that could damage the component while ensuring reliable retention.
Solution Approach 2:
The setting device incorporates force monitoring to detect when the plastic clip has been properly inserted. When the retaining mechanism engages with the pilot hole, the force profile changes, providing feedback that insertion is complete. This feedback mechanism prevents excessive force application that could damage the component while ensuring sufficient force for secure retention.
Data Source
AI summary
A process arrangement for carrying out a fully automatic setting process, in which a setting device drives a clip element into a component pilot hole. The process arrangement has a transfer unit, in particular a robot, to which the setting device is attached, and the transfer unit is adjustable between a pickup position, in which the setting device grabs the clip element, and a setting position, in which the setting device drives the clip element into the component pilot hole.