电动汽车的发展正在加速。中国为自己和汽车制造商设定了雄心勃勃的目标 — 到 2020 年所有汽车中有 12% 为电动汽车。法国希望 2040 年后只销售电动汽车。沃尔沃宣布计划在 2019 年停止生产内燃机汽车。伦敦出租汽车公司也已更名为伦敦电动汽车公司，表示有意进入电动汽车市场。新出租车将会有和它们的前辈一样的经典外观，但是会更干净和安静。英国政府已经认识到向电动汽车的转变，并于 2017 年 7 月宣布了一项开发蓄电池技术的重大投资计划。
工业创新自动化模块到包装试产线试点项目（简称 AMPLiFII）正在展示高效自动化如何有助于欧洲牵引蓄电池的竞争性生产。
专为小空间开发
在 AMPLiFII 试点蓄电池装配线内，特种机器制造商和系统集成商 Horizon Instruments 开发了一个高速单元电池抓取系统。这对技术总监 Daniel Bolton 和他的团队来说是一个独特的挑战。在设计蓄电池模块生产线时，他们面临着几个技术和实践限制：“我们有一个相对有限的空间来安装设备以及严格的预算参数，而且引入时间只有 7 个月。我们还需要找到一种方法对每个单元电池进行电测试，在需要时将其旋转，并以极高的精度快速将它们放入每个模块。" 试点工厂的核心任务之一是在将由 30 个单元电池组成的电池组抓取并放入蓄电池模块之前，同时测试它们的电流和电压。高成本和空间限制意味着不可能容纳 30 台单独的蓄电池测试仪。必须找到解决方案。Horizon Instruments 与华威大学的研究和教育小组 WMG 联合开发了一个定制的多路复用器接口，实现了使用单个蓄电池测试仪。这不仅节省了空间和资本成本，而且能够整理关于测试状态的比较数据。
A custom solution in eight weeks
After testing, the battery cells are aligned accurately and inverted if necessary. The pick and place system then inserts them into the module located on a conveyor. The plant can be configured to handle the exact number of battery cells, which can sometimes vary. 100 individual cells per module is typical, with a total weight of approximately 9 kg once assembled. Festo delivered a compact complete solution using Cartesian robot technology for fast and precise handling. “We didn’t need to coordinate multiple suppliers or worry about product compatibility”, explains Daniel Bolton. “Within just eight weeks of the order being placed we had a custom system. Festo also provided us with technical support throughout the design, installation and commissioning process.” With the new automation solution, each cell can be picked, rotated, aligned and placed in the modules within 1.2 seconds.
UK premiere
At the heart of the battery pick and place system is the Festo EXCH-60. The planar surface gantry is aimed at high-speed assembly operations where small, light mass-produced items need to be positioned quickly and flexibly. Powered by two fixed motors, the EXCH delivers an optimum dynamic response. By eliminating the need to use separate gantries for each axis, it delivers precise alignment. At speeds of up to 5 m/s and acceleration rates of up to 50 m/s2 it is capable of 100 picks per minute with a repetition accuracy of ±0.1 mm. For Steve Sands of Festo, using the EXCH is a significant step: “This project is the very first time that the planar surface gantry from Festo has been used in the UK. The automation technology now incorporated in this pilot line for electric vehicle batteries was originally developed for the construction of solar panels. It is ideal for handling delicate components and placing them with great precision.” The 2D planar surface gantry is controlled by a CPX valve terminal. It allows state-of-the-art electronics and pneumatics to sit on a single, stand-alone base.
Paving the way for the future
The new automation solution has generated interest beyond the machine building and automation technology sectors. For Professor Robert Harrison of the University of Warwick, the pilot project is proof “that the high-speed cell picker and other stations will allow us to demonstrate our ability to automate the cell-to-module packaging process and help pave the way to upscale to a full production plant.” Professor Harrison believes that the project will help develop the next generation of traction batteries for electric and hybrid vehicles. “It will combine the best human and automated assembly methods to manufacture battery packs and lay the foundations of a new UK automotive supply chain based around automated technology”, says the automation systems expert.
WMG
Coventry CV4 7AL
University of Warwick
United Kingdom
Area of business: Research and development
Horizon Instruments
Ghyll Industrial Estate
Heathfield, East Sussex
United Kingdom
Area of business: Design and build integrated automation solutions