Vision-Guided Connector Mating for Battery Assembly Inspection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional manual connection of connectors to plugs in battery system assemblies leads to issues such as missed inspections, increased worker fatigue, delayed inspection times, and poor connections, which can result in damage to the connectors.
Innovation Solution
An automatic connecting system using a vision unit to recognize plugs, a connector connecting unit with robots having different degrees of freedom to grip and connect connectors, and a control device to manage operations, ensuring precise and efficient connection of connectors to plugs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual connection method is used, then device complexity is reduced, but productivity decreases and manufacturing precision deteriorates
Solution Approach 1:
The system uses vision recognition to automatically identify plug positions and connector shapes, enabling the connection process to self-adjust without manual intervention. The control unit autonomously determines connection parameters based on recognized information, achieving self-service operation that improves productivity while managing complexity through automation.
Solution Approach 2:
The patent replaces manual mechanical operations with an automated system comprising vision recognition, control units, and robotic connection mechanisms. This substitution of human mechanical actions with automated mechanical and optical systems resolves the contradiction by improving connection speed and precision while containing system complexity through integrated automation.
2Manufacturing precision
If manual connection method is used, then device complexity is reduced, but manufacturing precision deteriorates due to poor connection and damage
Solution Approach 1:
The vision recognition unit provides real-time feedback on plug positions and connector shapes to the control unit, which adjusts connection parameters accordingly. This feedback mechanism ensures high connection precision by continuously monitoring and adapting to actual conditions, while the automated feedback loop manages complexity through systematic information processing.
Solution Approach 2:
The patent replaces imprecise manual mechanical operations with automated vision-guided mechanical systems. The vision recognition and controlled connection mechanisms eliminate human error in positioning and connection, achieving high manufacturing precision while containing complexity through integrated automation and control systems.
3Loss of time
If manual connection method is used, then ease of operation is maintained, but loss of time increases due to inspection time delay
Solution Approach 1:
The system performs automatic vision recognition and connection without requiring manual operation for each step. The self-service automation eliminates time-consuming manual inspection and connection operations, significantly reducing inspection time while the integrated system maintains operational simplicity through automated workflows.
Solution Approach 2:
The automated vision recognition and connection process enables continuous operation without the interruptions inherent in manual methods. The system maintains continuous useful action by eliminating idle time between inspection steps, reducing total inspection time while keeping the operation simple through automated sequencing.
4Reliability
If manual connection method is used, then ease of operation is maintained, but reliability decreases due to missing inspection portions
Solution Approach 1:
The vision recognition unit provides comprehensive feedback on all plug positions and connector conditions, ensuring no inspection portions are missed. This systematic feedback mechanism improves reliability by verifying each connection point, while the automated verification process maintains operational simplicity through integrated monitoring.
Solution Approach 2:
The patent replaces unreliable manual inspection with automated vision recognition and controlled connection. This substitution eliminates human error and missed inspection portions, significantly improving reliability while containing operational complexity through systematic automated procedures and verification.
Data Source
AI summary
An automatic connecting system for a battery system assembly (BSA) inspection, including a vision unit configured to recognize a plurality of plugs provided in a battery system assembly, a connector connecting unit configured to grip connectors, the connectors respectively matching the plurality of plugs among the connectors, move the gripped connectors to positions of those plugs, and then connect the connectors to the plugs, one or more processors configured to execute instructions, and a memory storing the instructions, an execution of the instructions configures the one or more processors to receive information about the plurality of plugs recognized by the vision unit and control the connector connecting unit to operate.