Custom Automation & Robotic 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.
LASER SYSTEMS
Industrial lasers are ideal for joining many materials together when integrated into high-performance automation.
Photon’s process begins with selecting the appropriate laser source for the application. Our experienced engineers and physicists evaluate the materials that need to be joined and specify the appropriate wavelength, power, laser spot size and beam delivery optics for the laser system. Material connections can be tested in our APPLICATIONS LAB, using a variety of available lasers and beam delivery optics. The welded or brazed part samples can be cut into sections and analyzed under microscopes to evaluate material flow, weld nugget geometry, presence of porosity or cracking, and cross-sectional area. Non-destructive testing is also available, using our CT SCANNER to evaluate the entire weld for consistency, depth and material composition.
Photon Automation has successfully integrated lasers into industrial settings since its early beginnings. Photon holds multiple patents for a novel welding method called PULSE SPREAD TECHNOLOGY, where we can dynamically change the output power of the laser as the beam is moved with scanning optics. This method is particularly useful for joining dissimilar materials, including metals with different melting points or different material thicknesses.
Our engineering staff has the knowledge and experience to design custom automated laser machines tailored to solve your unique laser welding or brazing application. Systems can include different types of robots, vision systems, 3D scanners, and sensing devices. Beam delivery options range from conventional beam delivery to advanced scanning systems with on-axis machine vision, integrated weld monitoring and automatic focus. Fully engineered and tested turn-key systems can be operated as stand-alone systems or can be integrated into a production line. All laser systems are certified to meet or exceed requirements for CDRH Class 1 or 2 safety.
Lasers with high beam quality and power density are used to drill or cut materials when integrated into robotic platforms. The quality of the cut is often determined by the amount of heat-affected area and thickness of the re-cast layer of the material. The high-brightness, narrow kerf of these laser machines can produce good edge quality at fast operating speeds.
The engineering staff at Photon Automation is experienced in designing custom automated laser machines tailored to solve your unique laser drilling or cutting application. Various robotic platforms can be used as a basis for the system, including six-axis, gantry-style and custom robot configurations. Fully engineered and tested turn-key systems can be operated as stand-alone systems or can be integrated into a production line. All laser systems are certified to meet or exceed requirements for CDRH Class 1 or 2 safety.
Product traceability can be realized with the use of laser systems for permanently marking or engraving the surface with text, barcode, logos or graphics. Lasers are capable of marking a multitude of materials and surfaces including: leather, wood, cardboard, painted or powder coated surfaces, aluminum, stainless steel and tool steel. Components ranging from industrial castings, medical products, surgical tools or electric vehicle batteries can be marked with permanent, traceable code or brand-specific logos.
AUTOMATED ASSEMBLY
Advanced manufacturing processes are integrated with robotics and various sensing methods to create an automated platform able to assemble the most critical components. Multiple processes can be combined onto a single system. Feedback devices provide the precision required for accurate, repeatable tasks. Photon’s simple, intuitive human interface, allows the user to operate and control complex operations on an automated platform with ease. Common interface screens reduce the learning curve involved with operating a Photon system. Automated assembly systems are capable of collecting and communicating critical data associated with the advanced manufacturing processes it executes. Users can remotely monitor the health and status of the systems. Critical data may be stored on the system or can be transferred to a server as desired.
INSPECTION & TESTING
Critical parts can be automatically inspected at high through put using Photon’s Automated Inspection Systems. Using high speed bulk feeding techniques, parts are automatically oriented and fed onto various inspection platforms including precision conveyors, glass dial tables or robotic handling systems. Inspection methods using high speed machine vision cameras, lasers and other sensors can detect subtle defects in components as they pass through the system. Parts can be sorted based upon physical attributes including size, color, or dimensions of key features. Photon’s operating software combined with a true real-time FPGA controller, create an inspection platform with lightning fast response, allowing for inspection speeds only limited by the ability to feed parts into the system.
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:
- 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.
- 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.
- 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.
- 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 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.
- 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.
- 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.
- 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.
- 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.