MOTION SYNCHRONIZED MULTI-TIER PALLET RACK AND BATTERY FORMATION APPARATUS HAVING THE SAME

A motion synchronized multi-tier pallet rack and a battery formation apparatus are provided. The pallet rack includes a fixation rack, two movable frames, and two actuators. The movable frames are coupled to two corresponding sides of the fixation rack and each includes telescopic arms, a motor, and a drive rod. The actuators are disposed on other the two corresponding sides of the fixation rack to drive the movable frames to move toward or away from each other. The telescopic arms are kinematically connected to the motor through the drive rod to extend from or retract into the movable frame. The battery formation apparatus includes a motion synchronized multi-tier pallet rack, a conveyor module, a formation cabinet, and a controller. The conveyor module carries a battery module. The controller controls the pallet rack to obtain the battery module from the conveyor module and place the battery module in the formation cabinet.

CROSS-REFERENCE TO RELATED APPLICATION

This non-provisional application claims priority under 35 U.S.C. § 119(a) to Patent Application No. 111212732 filed in Taiwan, R.O.C. on Nov. 21, 2022, the entire contents of which are hereby incorporated by reference.

BACKGROUND

Technical Field

The instant disclosure is related to a transportation machine applied in manufacturing industries, especially to a motion synchronized multi-tier pallet rack and battery formation apparatus having the same.

Related Art

For an automation apparatus of a production line known to the inventor, especially for a transportation machine applied in lithium battery formation process, in most cases, a single line transportation is performed. In other words, in most case, a batch of products can be transported in a one-time operation; if multiple batches of products are to be transported, the products need to be transported through multiple separate operations.

SUMMARY

Moreover, in a lithium battery formation process known to the inventor, lithium battery modules to be treated by the formation process (hereinafter, for the sake of convenience, referred to as lithium battery module) are initially carried to the vicinity of the formation cabinet through the conveyor. The lithium battery modules are taken from the conveyor by either a pallet rack or a robotic arm and then carried into the formation cabinet for the formation procedure. However, during a one-time operation, the pallet rack or the robotic arm known to the inventor can only perform the pick-and-place operation for the lithium battery modules in a single pallet, resulting in inefficient transportation performance of the pallet rack or the robotic arm. Consequently, the automation apparatus of the production line known to the inventor limits the overall production efficiency of products with a certain extent.

One of objects of one or some embodiments of the instant disclosure is to provide a motion synchronized multi-tier pallet rack and battery formation apparatus having the same. Therefore, according to one or some embodiments, a simplified mechanical design enables the simultaneous transportation for pallet in multi-tier configuration, thereby optimizing the accuracy and efficiency of product manufacturing, assembling, and transportation, and reducing time and labor costs.

To achieve the object, one or some embodiments provide a motion synchronized multi-tier pallet rack. The motion synchronized multi-tier pallet rack comprises a fixation rack, two movable frames, and two actuators. The two movable frames are respectively coupled to two corresponding sides of the fixation rack. The two actuators are respectively disposed on the two corresponding sides of the fixation rack and adapted to drive the two movable frames to move toward or away from each other. Each of the movable frames comprises a plurality of telescopic arms, a motor, and a drive rod. The telescopic arms are arranged into tiers and kinematically connected to the motor through the drive rod. For each of the movable frames, the motor is adapted to drive the telescopic arms to extend from or to retract into the movable frame.

In one or some embodiments, the fixation rack comprises a plurality of guiding rods extending along a first direction, each of the movable frames comprises a plurality of bushings, and each of the bushings is fitted over a corresponding one of the guiding rods. The two movable frames are guided by the guiding rods and the bushings to move toward or away from each other along the first direction. Each of the two actuators comprises a fixation mount and a movable head, the fixation mounts are respectively assembled on the two corresponding sides of the fixation rack, and the movable heads are respectively connected to the two movable frames. The actuator may be an electric cylinder, a pneumatic cylinder, or other equivalent device or mechanism that can perform linear movement.

In one or some embodiments, each of the movable frames further comprises a plurality of fixation plates and a plurality of gear assemblies. Each of the gear assemblies is assembled on a corresponding one of the fixation plates, and each of the telescopic arms is coupled to a corresponding one of the gear assemblies. For each of the movable frames, the gear assemblies are kinematically connected to a corresponding one of the drive rods, and each of the telescopic arms is driven by the corresponding one of the gear assemblies to extend from or retract into the movable frame along a second direction.

Each of the telescopic arms comprises a guiding mount and a movable arm, each of the movable arms comprises a gear rack, each of the guiding mounts is disposed on a corresponding one of the fixation plates, each of the movable arms is coupled to a corresponding one of the guiding mounts, and each of the gear racks is coupled to a corresponding one of the gear assemblies. Each of the movable arms is guided by the corresponding one of the guiding mounts to slide along the second direction.

In one or some embodiments, each of the movable arms comprises a first arm portion, a second arm portion, and a chain-pulley assembly. Each of the first arm portions is coupled to a corresponding one of the gear assemblies through a corresponding one of the gear racks. For each of the movable arms, the second arm portion is coupled to the first arm portion, and the chain-pulley assembly is coupled between the second arm portion and the first arm portion. The motion synchronized multi-tier pallet rack further comprises a plurality of position detectors, and the position detectors are disposed on the two corresponding sides of the fixation rack and arranged along one side of the movable arms in the second direction. Each of the movable arms further comprises two battery detecting devices respectively disposed on two corresponding sides of the second arm portion along the second direction.

To achieve the object, one or some embodiments provide a battery formation apparatus. The battery formation apparatus comprises at least one motion synchronized multi-tier pallet rack, at least one conveyor module, at least one formation cabinet, and a controller. The at least one conveyor module carries at least one battery module to be treated with a formation process. The controller is electrically connected to the at least one motion synchronized multi-tier pallet rack, the at least one conveyor module, and the at least on formation cabinet. The controller controls the at least one motion synchronized multi-tier pallet rack to obtain the at least one battery module from the at least one conveyor module and place the at least one battery module in the at least one formation cabinet.

In one or some embodiments, the at least one formation cabinet comprises a plurality of formation chambers. When the at least one motion synchronized multi-tier pallet rack carries a plurality of battery modules, the controller controls the at least one motion synchronized multi-tier pallet rack to place the battery modules in the formation chambers of the at least one formation cabinet simultaneously. Therefore, after the at least one motion synchronized multi-tier pallet rack places the battery modules in the formation cavities of the at least one formation cabinet simultaneously, the controller controls the two actuators to move the two movable frames away from each other and controls the telescopic arms to retract into the movable frames simultaneously.

As compared to the device known to the inventor, the pallet or apparatus according to one or some embodiments of the instant disclosure at least include following advantages: 1. the pallet rack or the apparatus has the function of simultaneous transportation and pick-and-place operation for multiple lines, apparently enhancing work efficiency for the transportation of production lines; 2. the pallet rack or the apparatus features a simpler and more reliable mechanical design, so that the pallet rack or the apparatus can be operated with minimized costs and occupied spaces; 3. the pallet rack or the apparatus incorporates an automated control function and a synchronized multi-mechanism operation design, so that the intelligent manufacturing can be achieved much easier.

DETAILED DESCRIPTION

Prior to the description of a motion synchronized multi-tier pallet rack and battery formation apparatus having the same according to one or some embodiments is provided, it is understood that in the following descriptions, similar elements are denoted by identical reference numbers. Moreover, the figures in the instant disclosure are provided merely for illustrative purposes and may not necessarily be drawn to scale, and not all the details of the instant disclosure may be shown in the figures.

Please refer toFIG.1andFIG.2.FIG.1illustrates a perspective view of a motion synchronized multi-tier pallet rack according to an exemplary embodiment of the instant disclosure, andFIG.2illustrates a front view of the motion synchronized multi-tier pallet rack according to an exemplary embodiment of the instant disclosure. As shown in the figures, in this embodiment, a motion synchronized multi-tier pallet rack1(hereinafter, for the sake of convenience, also referred to as rack) is provided, and the rack is a four-tier mechanism; however, the number of tiers of the rack can be flexibly adjusted corresponding to the number of tiers of a formation cabinet (not shown inFIG.1andFIG.2). The motion synchronized multi-tier pallet rack1comprises a fixation rack2, two movable frames3, and two actuators4.

The fixation frame2serves as a support structure for the main body of the motion synchronized multi-tier pallet rack1, ensuring the stability and functionality of the rack, particularly in terms of transportation. The two movable frames3are movably disposed on two corresponding inner sides of the fixation rack2along a first direction D1. Likewise, the two actuators4are respectively disposed on two corresponding outer sides of the fixation rack2, and the two actuators4are adapted to drive the two movable frames3to move toward or away from each other along the first direction D1.

Moreover, in some embodiments, each of the movable frames3comprises four telescopic arms31, and the number of the telescopic arms31corresponds to the number of tiers of the motion synchronized multi-tier pallet rack1in a paired manner. The telescopic arms31are arranged on each of the tiers of the two movable frames3in a paired manner, and the telescopic arms31can extend from or retract into the movable frames3. It should be noted that, for the sake of clarity to demonstrate the configuration of the telescopic arm31extending from the movable frame3, inFIG.1, pallet assemblies on the top three tiers of the motion synchronized multi-tier pallet rack1are omitted. In practical operation, the pallet assemblies are on all the four tiers of the motion synchronized multi-tier pallet rack1.

Moreover, please refer toFIG.3.FIG.3illustrates a perspective view of a fixation rack of the motion synchronized multi-tier pallet rack according to an exemplary embodiment of the instant disclosure. The fixation rack2comprises eight guiding rods21arranged on the two corresponding inner sides of the fixation rack2in a paired manner. All the guiding rods21extend along the first direction D1. Each of the movable frames3comprises four bushings34, and thus the motion synchronized multi-tier pallet rack1has eight bushings34arranged on two corresponding outer sides of the two movable frames3. Each of the bushings34is fitted over a corresponding one of the guiding rods21, so that the two movable frame3can be guided by the eight pairs of the guiding rods21and the bushings34fitted over the guiding rods21to move toward or away from each other along the first direction D1.

Furthermore, in this embodiment, each of the actuators4is an electric cylinder driven by a motor, and each of the actuators4comprises a fixation mount41and a movable head42. The fixation mounts41are disposed on the two corresponding outer sides of the fixation rack2. The movable heads42are located at the two corresponding inner sides of the fixation rack2, and the movable heads42are respectively connected to the two corresponding outer sides of the two movable frames3. The advantage of adopting the electric cylinder in this embodiment is that the range of the movement of the electric cylinder can be adjusted as needed so as to correspond to transported objects with different widths. However, it is understood that the actuator4is not limited to the electric cylinder; the actuator may be a pneumatic cylinder or other equivalent device or mechanism capable of performing linear motion.

Please refer toFIG.3,FIG.4, andFIG.5.FIG.4illustrates a side view of a movable frame of the motion synchronized multi-tier pallet rack according to an exemplary embodiment of the instant disclosure.FIG.5illustrates a perspective view of a movable assembly on the movable frame of the motion synchronized multi-tier pallet rack according to an exemplary embodiment of the instant disclosure. As shown, each of the movable frames3, in addition to the four telescopic arms31, further comprises a motor32and a drive rod33. Therefore, the motion synchronized multi-tier pallet rack1comprises two motors32and two drive rods33. Each of the four telescopic arms31is kinematically connected to a corresponding one of the motors32through the corresponding one of the drive rods33. For each of the movable frames3, the motor32is adapted to drive the telescopic arms31to extend from or to retract into the movable frame3.

Moreover, in some embodiments, each of the movable frames3further comprises four fixation plates35and four gear assemblies36. Therefore, the motion synchronized multi-tier pallet rack1comprises eight fixation plates35and eight gear assemblies36. Each of the gear assemblies36is assembled on a corresponding one of the fixation plates35, and each of the telescopic arms31is coupled to a corresponding one of the gear assemblies36. The four gear assemblies36of each of the movable frames3is kinematically connected to a corresponding one of the drive rods33, and each of the telescopic arms31is driven by the corresponding one of the gear assemblies36to extend from or retract into the movable frame3along a second direction D2.

Furthermore, in some embodiments, each of the telescopic arms31comprises a guiding mount311and a movable arm312. Therefore, the motion synchronized multi-tier pallet rack1comprises eight guiding mounts311and eight movable arms312. Each of the movable arms312comprises a gear rack313. Therefore, the motion synchronized multi-tier pallet rack1comprises eight gear racks313. Each of the guiding mounts311is disposed on a corresponding one of the fixation plates35, each of the movable arms312is coupled to a corresponding one of the guiding mounts311, each of the gear racks313is coupled to a corresponding one of the gear assemblies36, and each of the movable arms312is guided by the corresponding one of the guiding mounts311to slide along the second direction D2.

Furthermore, in some embodiments, each of the movable arms312comprises a first arm portion314, a second arm portion315, and a chain-pulley assembly316. Therefore, the motion synchronized multi-tier pallet rack1comprises eight first arm portions314, eight second arm portions315, and eight chain-pulley assemblies316. Each of the first arm portions314is coupled to a corresponding one of the gear assemblies36through a corresponding one of the gear racks313. For each of the movable arms312, the second arm portion315is coupled to the first arm portion314, and the chain-pulley assembly316is coupled between the second arm portion315and the first arm portion314.

In this embodiment, each of the tiers of the motion synchronized multi-tier pallet rack1is additionally equipped with two position detectors22. These position detectors22may employ an optical coupler configuration, typically comprising a light transmitter (often using infrared light) and a photoelectric receiver. In other words, in this embodiment, the position detectors22are disposed on the two corresponding inner sides of the fixation rack2and arranged along one side of the movable arms312in the second direction D2. In this embodiment, with the aid of the position detectors22, the controller7(as shown inFIG.6) can ascertain the movement status and position of the movable arms312. For instance, the controller7can determine whether the movable arms312are in an extended position or a retracted position.

In some embodiments, each of the movable arms312further comprises two battery detecting devices317. Therefore, the motion synchronized multi-tier pallet rack1comprises sixteen battery detecting devices317. For each of the movable arms312, the battery detecting devices317are disposed on two corresponding sides of the second arm portion315along the second direction D2. The battery detecting device may employ a photoelectric sensor configuration to determine the distance, absence, or presence of an object. Therefore, in this embodiment, with the aid of the battery detecting device317, the controller7(as shown inFIG.7) can ascertain whether the battery is held by two movable arms312.

Then, please refer toFIG.1andFIG.6.FIG.6illustrates a schematic view of a system for a battery formation apparatus according to an exemplary embodiment of the instant disclosure. As shown, in this embodiment, the battery formation apparatus comprises the motion synchronized multi-tier pallet rack1mentioned above, two conveyor modules5, a plurality of formation cabinets6(eight formation cabinets6are illustrated in the figures), and a controller7.

The controller7has a conventional structure and may include a processor, memory, storage media, communications devices, and input and output devices. For example, the controller7can be a standard microcontroller that includes a central processing unit (CPU), random access memory (RAM), read only memory (ROM) and input/output ports receiving input signals and sending output signals needed to control the system and to perform certain process steps as described herein. The functions described herein are generally programming instructions stored in memory and are performed by the logic of the CPU. Of course, the controller that performs the functions described herein could be a microprocessor using external memory or could comprise a combination of such a microprocessor or microcontroller combined with other integrated logic circuits. The controller7is generally incorporated into or works with a personal computer with a screen and input devices, such as keyboards, for inputting commands for process control and for monitoring the process control.

Moreover, in this embodiment, the conveyor module5is configured to carry battery modules to be treated with a formation process BM (hereinafter, for the sake of convenience, also referred to as battery module BM), the controller7is electrically connected to the motion synchronized multi-tier pallet rack1, the conveyor modules6, and the formation cabinets6. The controller7is configured to control the motion synchronized multi-tier pallet rack1to retrieve the battery module BM from the conveyor module5and place the battery module BM within the formation cabinets6, wherein each of the formation cabinets6comprises four formation chambers61arranged in tiers. Similarly, the conveyor modules5are organized into four tiers, with conveyors at each tier for transportation.

The operation of the apparatus is described as below. First, after the controller7controls the motion synchronized multi-tier pallet rack1to move to one side of the conveyor modules5, the controller7controls the telescopic arms31of the motion synchronized multi-tier pallet rack1to extend from the movable frames3simultaneously to be at two corresponding sides of the battery module BM. Next, the controller7controls the two actuators4to move the two movable frames3toward each other so as to grasp the battery module BM, and the controller7controls the telescopic arms31to retract into the movable frames3simultaneously. During this process, the battery modules BM are loaded into the motion synchronized multi-tier pallet rack1.

Then, the controller7controls the motion synchronized multi-tier pallet rack1to move to be in front of a corresponding one of the formation cabinets6and controls the two telescopic arms31held with the battery module BM (for the four tiers of the rack) to extend from the movable frames3in a synchronized manner and insert the battery module BM into the formation chambers61. Next, the controller7controls the two actuators4to move the two movable frames3away from each other to place the battery module BM within the formation chamber61. Consequently, the controller7controls the telescopic arms31to retract into the movable frames3simultaneously in preparation for subsequent transportations.

The above embodiments are merely examples for the purpose of illustration, and the scope claimed in the instant disclosure should be based on the claims, and is not limited to the above embodiments.