Vision-Guided Battery Module Bonding for Variable Cell Positions
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Solution Overview
Problem
Current battery module assembly apparatuses have low productivity due to reliance on a single vision unit for coordinate setting, difficulty in connecting cylindrical battery cells to busbars, and inability to efficiently handle battery modules with varying dimensions.
Innovation Solution
A battery module assembly apparatus with multiple bonding units and a vision unit that scans and adjusts the position of battery cells within a module carrier, allowing for precise bonding and height adjustment to accommodate various dimensions, enabling simultaneous bonding of multiple battery modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single vision unit and single bonding unit are used, then device complexity is reduced, but productivity is low due to sequential processing
Solution Approach 1:
The bonding apparatus is divided into multiple bonding units (first bonding unit, second bonding unit, etc.) that can simultaneously process different battery modules. Each bonding unit has its own bonding head and control system, allowing parallel processing of multiple modules to improve overall productivity while maintaining manageable complexity through modular design
Solution Approach 2:
Multiple bonding units are integrated into a single apparatus with a unified control system and shared vision unit. The bonding units work in parallel on different battery modules simultaneously, combining their capabilities to achieve higher throughput without requiring separate standalone systems for each bonding operation
2Manufacturing precision
If coordinates are set using only one vision unit, then device complexity is low, but manufacturing precision is insufficient due to lack of error correction
Solution Approach 1:
The vision unit captures images of battery modules before bonding, detects actual positions and dimensions, and provides feedback information to the control system. This feedback enables real-time adjustment of bonding parameters and position correction, ensuring high precision bonding even when modules have dimensional variations
Solution Approach 2:
The vision unit performs preliminary scanning and coordinate setting before the bonding process begins. By pre-detecting the positions and dimensions of battery cells and busbars, the system can plan and adjust bonding paths in advance, ensuring accurate bonding without requiring complex real-time adjustments during the actual bonding operation
3Productivity
If work is performed in a line with single processing station, then device complexity is low, but productivity is reduced due to sequential processing
Solution Approach 1:
The apparatus transitions from linear sequential processing to a multi-dimensional parallel processing configuration. Multiple bonding units are arranged spatially to work on different battery modules simultaneously, utilizing spatial dimensions rather than just temporal sequencing to improve productivity
4Adaptability or versatility
If a fixed dimension assembly apparatus is used, then manufacturing precision is maintained, but adaptability is reduced for battery modules with various dimensions
Solution Approach 1:
The bonding apparatus incorporates dynamic adjustment capabilities through the vision system and control unit that can adapt to different battery module dimensions. The system dynamically adjusts bonding parameters, positions, and paths based on real-time vision detection, maintaining high precision across various module sizes without requiring fixed-dimension tooling
Data Source
AI summary
The present invention relates to a battery module assembly apparatus with improved productivity and an assembly method using the same, more particularly a battery module assembly apparatus including a transfer unit configured to move a battery module having a cylindrical battery cell received therein in a state of being seated in a module carrier, a vision unit configured to check position information of the battery module and the module carrier, and a bonding unit configured to electrically connect an electrode of the cylindrical battery cell received in the battery module to a busbar, wherein the bonding unit includes one or more bonding units, and the position information checked by the vision unit is transmitted to the bonding unit, and an assembly method using the same.