[ SERVICES ]
BATTERY ASSEMBLY SYSTEMS
WITH A LASER FOCUS
PHOTON AUTOMATION, INC. provides custom laser systems services, automated assembly using robotics for advanced manufacturing processes, inspection and testing, and processes for assembling and testing EV batteries.
BATTERY ASSEMBLY SYSTEMS
Photon Automation, Inc. has developed automated processes for assembling and testing EV batteries. Photon has designed and built manufacturing lines for EV battery assembly using these processes. Various technologies can be used in the manufacturing of battery assemblies including:
CELL PROCESSING
- Cells can be robotically handled, including automatic unloading from boxes and placement on the battery assembly.
- Individual cells can be electrically tested for OCV and ACIR and values can be compared with factory specifications.
- Decay factors may be used, comparing the results of the measurement with normally expected discharge rates over time.
- External features of the cells can be inspected with machine vision or 3D scanning techniques.
- Data for each cell can be stored or shared for 100% traceability.
ADHESIVE DISPENSING
- In some instances it may be desirable to use adhesives in a battery assembly.
- Adhesives ranging from single part UV curable adhesive, RTV, multi-part structural, or thermal adhesives may be used for battery assembly.
- High efficiency, fully automatic dispensing systems can be used, powered by positive displacement, servo powered, precision dispensing devices mounted to robotic motion systems.
- Machine vision can be used for robot guidance, adhesive bead measurement or verification of adhesive presence.
ROBOTIC ASSEMBLY
- Robots are used for automated assembly of batteries.
- Cartesian gantry-style robots can be used for high-speed, precision assembly tasks.
- Six-axis robots are used for more complex assembly tasks where component manipulation is required.
- Machine vision is commonly used for robot guidance, assembly verification, and for metrology purposes.
ASSEMBLY PRESSING
- Servo powered, precision-controlled pressing is often required for battery assembly.
- Force and position monitoring is used for achieving accuracy when assembling press-fit components.
MACHINE VISION SYSTEMS
- Machine vision is used for applications ranging from robot guidance, part locating, feature identification, feature measurement, assembly verification and metrology.
- Various vision platforms can be integrated with resolutions up to 21 megapixels in both monochrome and color.
- Imaging optics includes lenses with preset apertures, locking focus adjustments and range from conventional lenses to telecentric configurations.
- Lighting for vision applications can use multiple frequency light sources deployed in dark-field, light-field, structured, or combination configurations.
- Vision systems can include 2D barcode identification and decoding.
- 3D vision scanning can be used for locating parts or features of parts in three dimensions, for use in robotic guidance, feature detection, assembly verification or metrology.
- Confocal laser measurement is used for precision, non-contact distance measurement.
LASER WELDING
- High powered lasers are used for joining components to make electrical connections.
- Laser welding is used for busbar connections for high current joints.
- Laser welding can also be used for connecting conductors directly to cells.
- Dissimilar metals can be welded using Photon Automation’s patented Pulse Spread Technology, allowing the laser power to be dynamically adjusted at high speed relative to the beam position.
- Weld monitoring can be used to dynamically measure the weld process for real-time verification of weld quality.
- Multiple laser wavelengths can be considered for welding materials used for current carrying applications depending upon the material composition.
TESTING
- Electrical testing can be conducted on various portions of battery manufacturing including:
- Individual cell open circuit DC voltage and AC internal resistance.
- Sub-assembly electrical test.
- Micro-ohm resistance measurements for determining conductor connection integrity.
- High-current testing using thermal imaging analysis.
- End of line testing including monitoring of charge/discharge cycle electrical and thermal characteristics.
MATERIAL HANDLING
- Automated assembly lines include methods for transporting product from one operation to the other.
- High-speed high-accuracy transport methods, including the use of servo powered conveyance, are used to minimize dwell time and travel time between operations.
DATA MANAGEMENT
- Process data can be collected throughout the battery assembly process.
- Data is stored for each process and remains part of the assembly record for the finished product.
- Dynamic adjustments to the assembly process can be made based upon data collected.