Once assembled, battery modules for electric vehicles (EV) must be mounted on top of a liquid gap filler paste in the battery tray. This can be achieved with tightening, but the process must be fully controllable so the thermal transfer is not compromised. The answer is automation and robot guidance.
The soft joint behavior of the gap filler presents a challenge in the assembly of EV battery modules due to the tendency of gap filler adhesive to squeeze out between the module and tray. This can result in air remaining trapped within the battery module. A fully controllable tightening strategy is required to guarantee even distribution and full contact between the battery modules and the thermal compound (gap filler).
With a portfolio ranging from the PF6 FlexSystem controller, and the PowerPICK3D detection sensor to the MONO3D robotic guidance system, we offer an integrated, fully automated, and controlled module assembly process solution answering the utmost demands.
Ensures continous tightening process, quality assurance and traceability
Our industry-leading nut-runners provide a multi-spindle controlled electronically by the Atlas Copco PF6 FlexSystem, a combination that ensures a continuous tightening process, quality assurance, and traceability via data collection and visualization. Working synchronously in the final tightening process reduces the assembly cycle time, and each module is fixed evenly in the tray. Optimal contact, ensuring thermal transfer, is achieved by employing a programmed tightening strategy with a precise tightening sequence.
The compact size of the multi-spindle FlexSystem can save up to 97% floor space and 90% cable length and save energy thanks to low standby energy consumption.
Time and cost efficiency to the module assembly process
Precise positioning of the applicator unit is of absolute importance for the assembly process to be performed to the highest quality standards. MONO3D is a precise robot guidance solution for multi-spindle systems. It enables unsorted components to be automatically picked from a pallet or component carrier, making it a time and cost-efficient addition to the module assembly process. The system determines the position of an object in all six degrees of freedom in less than one second, after which the information on the component´s exact position is then used for precise robot path planning.
MONO3D is a highly flexible system that is easy to configure to any requirements and can be ready for use within a matter of hours with any robot.
Atlas Copco offers a comprehensive end-to-end module assembly solution addressing the need for controllability and automation throughout the production process. Innovative industrial ideas coming alive for real production needs.
Fully automated battery assembly lines require machine vision technology to guarantee a collision-free assembly process. The ISRA VISION PowerPICK3D ensures a consistently high and reliable inspection quality based on 3D images that recognize very small parts, irrespective of their geometry or material. When foreign parts are detected, the assembly process is stopped accordingly, avoiding serious damage in the battery assembly process. With a measurement time of less than 500ms, the PowerPICK3D scanner offers ultra-fast process control abilities.
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