Apparatus for positioning tooling devices relative to a battery

A programmable control mechanism for positioning a tool head relative to a battery. The programmable mechanism includes a conveyor means for moving the battery along a first dimensional axis into a work station of the mechanism, a sensing means detects the leading and trailing edges of the battery and means responsive to the sensing means and the conveyor means generates a signal representing the dimensional length of the battery. The signal is utilized by a minicomputer to select a work program suited for that length of battery from a memory bank containing a plurality of such programs. The minicomputer utilizes a selected program to position the tool head relative to the battery so that various successive operations may be performed on the battery by any one of a variety of tools.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
The present invention generally relates to a programmable control work 
performing mechanism and, more particularly to a method and mechanism for 
positioning a tool support head relative to a battery. 
2. Description of the Prior Art 
In the manufacture of electric storage batteries, such as the lead-acid 
batteries used in automobiles, groups of plates and separators are placed 
within a battery case. The plates and separators are divided into a 
plurality of cells within the case by a series of non-conductive 
partitions. An intercell connection is formed generally by disposing the 
faces of plate connecting lugs adjacent opposite sides of an aperture in 
the partition wall. A mechanical and electrical joint between the adjacent 
connectors is formed by extruding a portion of each connector into contact 
within the aperture and applying a welding current to melt the extruded 
connector. 
Various mechanical processes and tests are required in assembling the 
aforedescribed storage batteries. Among these processes and tests are: (1) 
producing an aperture in the partition wall; (2) forming an intercell 
connection therethrough; (3) testing for a voltage drop between the cells 
and (4) pressure/vacuum testing the battery casing. 
The intercell connections present various problems from a manufacturing 
standpoint. It is necessary to ensure a secure mechanical and electrical 
connection, but it is also important to prevent leakage of the electrolyte 
solution between the cells, U.S. Pat. No. 4,046,062 to Matter discloses a 
common method of effecting a through-the-partition weld of battery cell 
connectors. 
Another problem encountered is the proper alignment of the intercell 
connecting lugs with each other and the openings in the partition. Modern 
battery manufacturing lines are commonly designed to accommodate a 
plurality of sizes of batteries. This necessarily means that a number of 
tools are required to effect the aforementioned processes and tests and 
their movement relative to a particular battery is dependent upon the 
number of cells in the battery and the horizontal spacing and vertical 
location of the interconnections. Obviously, to manually move the various 
tools successively from one cell interconnecting position to another is a 
time consuming operation which would destroy the production efficiency of 
the battery manufacturing line. There is, therefore, a need for an 
automated mechanism for effecting the automatic positioning of the various 
tools in successive alignment with the desired positions of the partition 
interconnections for the particular size battery. The problem is further 
complicated by the fact that the successive through-the-partition 
interconnections or similar operations must be accomplished at locations 
which are horizontally spaced from each other in two directions and, at 
the same time, the tools must be moved vertically into position to effect 
each interconnection or similar operation and then vertically retracted 
prior to moving to the next interconnection position. 
SUMMARY OF THE INVENTION 
According to the present invention, there is provided a programmable 
control device for successively accurately positioning a tool support head 
relative to a battery in a universal positioning machine. A conveyor 
means, such as an endless conveyor belt, is driven by a first stepping 
motor. The conveyor belt moves the battery along a first dimensional axis 
path into a work station of the machine. A photocell detects the leading 
and trailing edges of the battery as it passes through a beam of light 
prior to entering the work station and generates an enabling signal to a 
counter. The counter counts the number of steps taken by the stepping 
motor to move the battery completely past the photocell and ceases 
counting when the light beam is restored. The number contained in the 
counter represents a dimensional characteristic of the battery. A 
minicomputer utilizes that dimensional characteristic to select a specific 
program based on that particular characteristic from a plurality of 
positioning programs stored in the minicomputer memory. The minicomputer 
utilizes the selected program to successively horizontally and vertically 
position the tool support head relative to the battery partition for 
proper operation of the tool carried by the support head. In the preferred 
embodiment, a second stepping motor and a third stepping motor operate to 
move the tool support head along the two other perpendicular axis paths. 
When the tool support head is in the proper position for a desired 
operation to be effected, the minicomputer generates a signal to a tool 
power control unit. The power control initiates the desired operation and 
instructs the minicomputer when the operation is completed, so that a new 
battery can be moved in. 
In an alternative embodiment, the selection of the required operation 
program for the minicomputer may be made manually. 
It is, therefore, an object of the present invention to provide an improved 
method and apparatus for successively positioning a tool support head 
relative to a battery for effecting through-the-partition interconnections 
and similar operations on the battery. 
It is also an object of the present invention to provide a 
through-the-partition interconnection positioning machine which is 
automatically adaptive to variations in battery size, hence, variations on 
the number and location of the operations to be performed. 
Other objects and advantages of this invention will become more apparent 
during the course of the following description, when read in conjunction 
with the accompanying drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
Referring now to drawings, there is illustrated in FIG. 1, a universal tool 
positioning machine 10 having a tool support head 12 by which a number of 
tools are positioned relative a workpiece such as a battery 14. 
In the preferred embodiment of the invention, the universal machine 10 is a 
device for positioning a number of tools for performing successive 
operations through several partitions P which divide a typical battery 
into a plurality of cells. More broadly stated, the invention contemplates 
moving a tool head 12 successively relative to a battery for performing a 
plurality of successive operations on the battery according to a 
predetermined program selected in accordance with the size of the battery. 
A workpiece, such as the battery 14, is carried into a work station of the 
machine 10 by a conveyor means, such as an endless conveyor belt 16. The 
conveyor belt 16 is supported between two end rolls (not shown) by a 
plurality of transverse rollers (not shown) to provide for relatively 
frictionless movement of the conveyor belt 16 as it passes through the 
machine 10. The conveyor means includes a first stepping motor 18, which 
is schematically illustrated in FIGS. 2 and 3. The first stepping motor 18 
rotates a drive shaft 20 which in turn rotates one of the two conveyor end 
rolls. The driven end roll frictionally engages the inner surfaces of the 
conveyor belt 16, causing it to move around the two end rolls. Thus, the 
conveyor belt 16 moves the battery 14 along a first dimensional axis, 
designated generally by X, into the work station of the machine 10. 
Prior to entering the work station, the battery 14 passes through a sensing 
means for detecting the leading edge and trailing edges of the battery 14 
as it moves on the conveyor belt 16. In the illustrated embodiment, the 
sensing means consists of a photocell 22 and an associated light source 24 
(shown in FIGS. 2 and 3). The light source 24 focuses a narrow beam of 
light 26 onto the photocell 22. The light beam 26 passes above the 
conveyor belt 16 in a direction generally perpendicular to the movement of 
the battery 14 through the machine 10. As the leading edge of the battery 
14 passes, the photocell 22 detects the interruption of the beam 26. 
Similarly, when the trailing edge of the battery 14 passes, the photocell 
22 detects the restoration of the beam 26. Such a photoelectric sensing 
means is well known in the art and it will be appreciated that any sensing 
device which can detect the leading and trailing edges of the moving 
battery 14 is contemplated as within the scope of the present invention. 
The first stepping motor 18 and the photocell 22 are connected to means for 
generating a signal representing a dimensional characteristic of the 
battery 14. As illustrated in FIG. 3, a counter 28 is connected to the 
first stepping motor 18 so as to register one count for each step movement 
of the motor 18. The counter 28 is also connected to the photocell 22 so 
as to function as an enabling switch. When no battery 14 is present, the 
light beam 26 is uninterrupted and the photocell 22 generates a signal 
which disables the counter 28. As the leading edge of a battery 14 passes 
through the light beam 26, the photocell 22 detects the disruption of the 
beam 26 and generates an enabling signal to the counter 28. The counter 28 
counts the number of steps taken by the first stepping motor 18 as it 
moves the conveyor belt 16 and the battery 14. When the trailing edge of 
the battery 14 passes by, the light beam 26 is restored and the photocell 
22 again disables the counter 28. Thus, the count number contained in the 
counter 28 represents a dimensional characteristic of the battery 14 which 
has just passed by. 
As illustrated in FIGS. 4 through 7, a number of tools may be employed in 
the automated production of batteries. These tools, among others, include 
a case punch head tool 30 (FIG. 4), a welding head tool 32 (FIG. 5), an 
inter-cell milli-volt drop tester 34 (FIG. 6), and a battery case 
pressure/vacuum tester head 36 (FIG. 7). 
The positioning of these tools 30, 32, 34, and 36 relative to the battery 
14 is critical to the proper construction of the battery. For an automated 
machine to be practicable, it must be sensitive to variations in battery 
size and adjust the position of the tools for specified operations as well 
as perform the required operations in rapid fashion. To accomplish these 
results, the present invention provides a storage means for programming a 
plurality of specified work programs based on the dimensional 
characteristics of each battery fed to the machine and a processing means 
responsive to the signal generating means for selecting a work program 
from the storage means. 
In the illustrated embodiment, the processing means consists of a 
minicomputer 38 which is connected to the counter 28. The storage means 
can be a memory bank 40 connected to the minicomputer 38. The structures 
of the computer 38 and its associated memory bank 40 are conventional in 
the art. For example, such an arrangement is set forth in detail in U.S. 
Pat. No. 3,725,651 to Cutter. 
The memory 40 is programmed with a plurality of different work programs. 
Each program contains data and instructions relating to the proper 
positioning of the tools 30, 32, 34, or 36, based upon differing 
dimensional characteristics of the battery 14. As the battery 14 enters 
the work station, the counter 28 generates a signal representing the 
dimensional characteristic of that battery 14. The minicomputer 38 is 
responsive to the counter 28 and selects a work program for a specified 
tool from the memory 40 which corresponds to a battery of that specific 
characteristic. When the minicomputer 38 has selected the proper work 
program, it generates a reset signal to the counter 28 to clear the count 
to zero until the next battery to be worked on interrupts the light beam 
26 and enables the counter 28 to count again. 
Having retrieved the proper work program from the memory 40, the 
minicomputer 38 generates signals which control the conveyor means 16 and 
a servomotor means so as to properly successively position the tool head 
12 relative to the battery 14 for a series of desired operations by 
whatever tool is mounted on the tool support 12. The servomotor means 
consists of a second stepping motor 42 and a third stepping motor 44 which 
move the tool head 12 along two other dimensional axis paths. The second 
stepping motor 42 and the third stepping motor 44 operate drive shafts 46 
and 48, respectively, to move the tool head 12 along other dimensional 
axes, designated as Y and Z. The drive mechanisms are conventional in the 
art and form no part of the present invention. 
The signals generated by the minicomputer 38 instruct the three stepping 
motors 18, 42, and 44 to operate so as to position the tool head 12 
relative to the battery 14 for a desired operation. The operation of the 
stepping motors 18, 42, and 44 is monitored by the minicomputer 38 to 
ensure compliance with a given request. 
When the stepping motors 18, 42, and 44 have positioned the battery 14 
properly, a signal is generated to a power control unit 50 (see FIG. 3) 
which, in turn, controls the operation of the tool. The power control unit 
50 not only initiates the operation of the respective tools but instructs 
the minicomputer 38 as to when the operation is completed. The stepping 
motors 18, 42, and 44 will then be activated by the minicomputer 38 to 
move the tool head 12 and the battery 14 into position for the next 
operation, or to move the battery 14 out of the machine 10 and permit the 
entry of the next battery. 
The present invention also includes a manual program selector unit 52 (see 
FIG. 3) which is connected to the minicomputer 38. The manual program 
selector 52 permits an operator of the machine 10 to select a specific 
work program from the memory bank 40. When the minicomputer 38 receives a 
signal from the manual program selector unit 52, it will select the 
requested program from the memory bank 40 and repeatedly utilize that 
program until instructed by the manual program selector unit 52 to return 
to normal operation. When a program is manually selected, the minicomputer 
38 will ignore any signal generated by the counter 28. Thus, the counter 
28 and the photocell 22 may be turned off by the minicomputer 38 when a 
manually selected program is in use. The use of the manual program 
selector unit 52 is more efficient than the normal sensing and selecting 
operation performed by the minicomputer 38 when it is known that only a 
particular size battery, requiring a particular work program, will be 
received by the machine 10. 
Briefly, the case punch head tool 30 illustrated in FIG. 4 is detachably 
connected by suitable means (not shown) to the tool head 12 and moved into 
various operating positions for successively producing apertures 54 in the 
partitions P of the battery 14. Generally, the tool 30 comprises a 
U-shaped mounting frame 56 adapted to be connected to the machine tool 
head 12. The frame 56 is provided with a pair of horizontally disposed 
parallel rails 58 and 60 for carrying two relatively movable carriages 62 
and 64. Each carriage 62 and 64 is provided with a depending tool holder 
66 and 68, respectively, with the lower extremity of the tool holder 66 
carrying a punch 70 and the lower extremity of the tool holder 68 carrying 
an axially aligned punch receiving aperture 72. The carriages 62 and 64 
may be moved relative to each other by a power cylinder 74. In operation, 
the punch and die tool 30 are moved into a working position about the 
battery partition P with the tool holder 66 and 68 on opposite sides 
thereof and are moved relative to each other to produce the apertures 54 
in the partitions P. The operation of the tool 38 is controlled by a 
suitable work program as previously described. 
Referring now to FIG. 5, the welding head tool 32 illustrated therein is 
adapted to be detachably connected (not shown) to the tool head 12 and 
moved into a working position as previously described for fusing a pair of 
opposed, upstanding, cell connected lugs 76 and 76' together. More 
particularly, the welding head tool 32 includes an electrode unit having a 
pair of opposed copper electrode jaws 78 and 78' for squeezing and fusing 
the opposed battery lugs 76 and 76' together through the apertures 54 in 
the battery partitions P. A separate extruder unit 80 having a pair of 
opposed forging plungers 82 and 82', which pass through apertures in the 
electrode jaws 78 and 78', first extrudes portions of the lugs 76 and 76' 
into the apertures 54 of the partitions P. Then a welding current is 
passed through the electrode jaws 78 and 78' to fuse the lugs together. 
The welding head 32 is more fully described in a copending application 
Ser. No. 178,808, filed Aug. 18, 1980 U.S. Pat. No. 4,368,373, and 
assigned to the same assignee. The operation of the welding head 32 is 
controlled by a suitable work program as described above. 
Briefly, the inter-cell milli-volt drop tester 34 illustrated in FIG. 6 is 
detachably connected by suitable means (not shown) to the tool head 12 and 
moved into a working position as previously described for ascertaining 
voltage drops, if any, between adjacent battery cells, thus testing the 
adequacy of the inter-cell weld connections. Generally, the tester 34 
includes a conventional electronic device 84 having a pair of depending 
electrodes 86 and 86' for contacting the vertically extending flange 
portions 88 and 88' of the battery cell connecting lugs 76 and 76', 
respectively. Also a pair of rod type electrodes 90 and 90' depend from 
the device 84 for contacting the horizontal flange portions 92 and 92' of 
the battery lugs 76 and 76'. The operation of the tester 34 is 
conventional and is controlled by a suitable work program as previously 
mentioned. 
Referring now to FIG. 7, the case pressure/vacuum tester 36 illustrated 
therein is adapted to be detachably connected to the tool head 12 by means 
(not shown) and moved into a working position as described above. Briefly, 
the tester 36 comprises a housing 94 defining a chamber having a plurality 
of suction devices 96 depending therefrom for contacting the top surface 
98 of the battery 14 over apertures 100 provided therein. The operation of 
the pressure/vacuum tester 36 may be controlled by a suitable work program 
as described above. 
Although this invention has been illustrated and described in this 
preferred embodiment, it will be apparent to those skilled in the art that 
various changes and modifications may be made therein without departing 
from the spirit of the invention.