Patent Description:
A battery module is formed by stacking a plurality of battery cells, and an exterior thereof is covered by a casing. In order to prevent the temperature inside the casing from rising in a manufacturing process of the battery module, fix the cells in place, and protect the cells, a liquid resin as a heat dissipation member may be injected into a space inside a pack to compactly fill the pack. In order to check whether the resin is fully hardened in a state of being completely filled inside the pack, a plurality of check holes are formed in a line on an outside of the casing, and a tape, which is an attachment member for covering the check holes, is attached to the casing. Openings are perforated in the tape at positions corresponding to the check holes. When the resin is filled in the pack to completely occupy the space and hardened, a protruding portion is formed through the check hole and the opening of the tape.

When the tape attached to the casing of the battery module is removed (primary removal) in a test process, a portion of the resin protruding through the opening of the tape is removed together with the tape, but a portion of the resin protruding outward through the check hole still remains and thus is removed (secondary removal) with a knife, which is a removal device. Then, an outer surface of the casing is cleaned to be flat, so that an exterior of the casing is smoothly finished.

However, in the present process, each of two operators performs tape removal, resin removal, and visual inspection. As described above, there are problems in that two operators are required, each operator has a different removal process speed, and efforts are required to remove the tape and the resin.

In order to solve the above problems, the inventor has developed an automatic removal system for automatically removing a tape and a resin of a battery module, which automatically removes the tape and the resin using a multi-axis automatic robot.

Further prior art is disclosed in <CIT>, <CIT>, <CIT>, <CIT>, <CIT> and <CIT>.

The present invention has been devised to solve the above problems, and the present invention is directed to providing an automatic removal system for automatically removing a tape and a resin of a battery module, having a new structure capable of automatically, quickly, and reliably removing the tape and the resin exposed to the outside of the battery module, increasing production yield, and reducing costs by reducing man-hours.

According to an aspect of the present invention, this object is accomplished by an automatic removal system for automatically removing a tape and a resin exposed to an outside of a battery module comprising the features of patent claim <NUM>.

Dependent claims are directed on features of preferred embodiments of the invention.

According to the present invention, a tape and a resin of a battery module can be automatically removed using an automatic multi-axis robot, so that an operation is fast and accurate, and an operation speed can be significantly increased.

An automatic multi-axis robot of the present invention can freely pivot, bend, and move in parallel, and thus, by attaching a device for removing a tape and a resin of a battery module, the tape and resin of the battery module can be removed in various ways, so that adaptability according to the work environment is excellent and compatibility is also excellent.

The automatic removal system of the present invention is unmanned equipment, and thus can reduce man-hours and labor costs according to the reduced man-hours, and can be economical and cost-saving.

<FIG> is a configuration diagram of an automatic removal system <NUM> for removing a tape and a resin of a battery module B according to the present invention. A tape T is presented as an example of an attachment member, a resin R is presented as an example of a heat dissipation member, and other members that achieve the same function are also applicable. These terms do not limit the scope of the present invention.

The automatic removal system <NUM> of the present invention includes a controller <NUM> serving as a main control unit (MCU) of the entire system, an automatic multi-axis robot <NUM>, a transfer shuttle <NUM>, an aligner <NUM>, a transfer module <NUM>, a removal assembly <NUM>, a blowing module <NUM>, and a cleaning device <NUM>. These members are connected to the controller <NUM> in a wired or wireless manner and driven by a signal of the controller <NUM>.

The battery module B moved by the transfer module <NUM> moves along the transfer shuttle <NUM> to be fixed in place in the aligner <NUM>, and the tape T and the resin R are removed by driving the removal assembly <NUM> coupled to the automatic multi-axis robot <NUM>. The removal assembly <NUM> is cleaned by the cleaning device <NUM>, the tape T is collected in a collector (not shown in <FIG>), the battery module B, after being cleaned, moves for another operation, and the automatic multi-axis robot <NUM> returns to its original position and then waits for the supply of a next battery module B.

According to the present invention, a large amount of tapes T and resins R of the battery module B may be removed quickly and reliably by repeating the above automatic removal operation cycle.

<FIG> illustrates an example in which the automatic removal system <NUM> of the present invention according to <FIG> is implemented. Illustration and description of a motor, a pneumatic actuator, a cylinder, a cable, and the like, which are members naturally provided in a conventional automatic process system, will be omitted in the following description except in special cases so that the present invention is clearly understood.

The battery module B in which processes of stacking battery cells, injecting the resin R, and attaching the tape T are completed moves from an unloader <NUM> to a conveyor <NUM> and moves along an x-axis direction. The conveyor <NUM> is disposed long along the x-axis direction, and the automatic multi-axis robot <NUM>, the transfer shuttle <NUM>, and the aligner <NUM> are generally arranged along a y-axis direction that is perpendicular to the x-axis direction. The unloader <NUM> and the conveyor <NUM>, and the movement of the battery module B according to the unloader <NUM> and the conveyor <NUM> are illustrated based on the present process system, and may be modified in various ways, such as supplying the battery module B directly to a front side of the transfer shuttle <NUM>.

The transfer module <NUM> is installed adjacent to the conveyor <NUM> and the transfer shuttle <NUM>. The transfer module <NUM> includes a fixed stand <NUM> positioned at a lower portion thereof, a pivot body <NUM> which is installed on the fixed stand <NUM> and horizontally rotatable and in which an MCU is embedded, and an extension arm <NUM> which extends long from one side of the pivot body <NUM> and is vertically and horizontally rotatable. A battery gripper <NUM>, which is heavy and has a tong shape, is installed at a front-side end of the extension arm <NUM>. Grippers of the battery gripper <NUM> are pivotable between a grip position at which the grippers rotate so that front ends thereof are close to each other and firmly grip the battery module B, and a non-grip position at which the grippers rotate so that the front ends thereof are spaced apart from each other and are separated from the battery module B.

When a battery position detection sensor (not shown in <FIG>) detects that the battery module B has arrived at a predetermined position of the conveyor <NUM>, the extension arm <NUM> pivots downward by a predetermined angle to face both side surfaces of the battery module B, the battery gripper <NUM> moves inward toward the side surfaces of the battery module B and presses the side surfaces, and this position is the grip position. In this state, the extension arm <NUM> rotates upward, and the pivot body <NUM> revolves toward the transfer shuttle <NUM>, and then, the extension arm <NUM> rotates downward to place the battery module B on the transfer shuttle <NUM>. When the transfer process of the battery module B is completed in this manner, the battery gripper <NUM> may be switched to the non-grip position.

An example of the transfer module <NUM> has been described above, and a device of any structure may be appropriately employed as along as it performs a function capable of moving the battery module B from the conveyor <NUM> to the aligner <NUM>. An application target of the transfer module <NUM> is not limited, for example, the transfer module <NUM> is also applicable to the battery module B transferred by being loaded on a rotary turntable instead of the conveyor <NUM>.

Next, before describing the structure of the transfer shuttle <NUM> and the aligner <NUM>, the automatic multi-axis robot <NUM> and the removal assembly <NUM> of the present invention will be described first.

In the automatic removal system <NUM>, the automatic multi-axis robot <NUM> is spaced apart from a platform <NUM>, on which other members are installed, to secure a sufficient working space.

As shown in <FIG>, the automatic multi-axis robot <NUM> of the present invention has a multi-joint structure including a body <NUM>, a first robot arm <NUM> connected to the body <NUM> through a boss <NUM> and extending upward, and a second robot arm <NUM> extending horizontally from an end of the first robot arm <NUM>. A pivotable drive arm <NUM> is coupled to a front end of the second robot arm <NUM>, and a coupling portion <NUM> coupled to the removal assembly <NUM> is formed at a front end of the drive arm <NUM>. An MCU is embedded in the body <NUM> and communicates with the controller <NUM>. The first robot arm <NUM> freely rotates in a three-dimensional space to set default vertical and horizontal positions, and the second robot arm <NUM> performs rotational and bending movements. The drive arm <NUM> is connected to a spindle of the second robot arm <NUM>, and bends and pivots independently.

An example of the automatic multi-axis robot <NUM> has been described above, and the structure of the automatic multi-axis robot <NUM> may be appropriately changed according to a work environment. For example, the coupling portion <NUM> may be manufactured as a finger type or the arm may be used as an independent arm that performs other functions, and the automatic multi-axis robot <NUM> of a compact structure may be integrated into the platform <NUM>.

The coupling portion <NUM> of the automatic multi-axis robot <NUM> is coupled to the removal assembly <NUM>, and the latter freely moves, pivots, and performs rotation and joint movements due to the driving of the former.

As shown in <FIG>, the removal assembly <NUM> of the present invention includes a base <NUM> having a flat plate shape, and first removal devices <NUM> including rods 54a arranged side by side along one side of a lower surface of the base <NUM> and each extending downward vertically and grippers 54b each formed integrally with a front end of the rod 54a and having a tong shape. A front surface of the base <NUM> is coupled to the coupling portion <NUM> of the drive arm <NUM> of the automatic multi-axis robot <NUM>.

Similar to the battery gripper <NUM>, the grippers 54b are pivotable between a grip position at which grippers thereof rotate so that front ends thereof are close to each other and firmly grip the tape T, and a non-grip position at which the grippers rotate so that the front ends thereof are spaced from each other and are separated from the tape T.

The gripper 54b may be modified in various ways, for example, the gripper 54b may take the form of a pad having a flat plate shape and a mesh structure or embossing to which the tape T can be attached.

A plurality of support brackets <NUM> are installed side by side in a side opposite to one side, in which the first removal devices <NUM> are arranged, and a second removal device <NUM> serving as a knife for removing the resin R is mounted to an inlet portion of each of the support brackets <NUM>.

An example of the structure and operation of the removal assembly <NUM> has been described above, and it is obvious that the following modifications are possible.

First, the size and number of the first and second removal devices <NUM> and <NUM> may be variously changed according to the size of the battery module B, and the alignment positions and number of check holes, for example, when the tapes T are arranged only in a line in the battery module B, only one of the first and second removal devices <NUM> and <NUM> is installed. In this regard, it is preferable that the removal assembly <NUM> of the present invention be of an exchangeable type detachable to the automatic multi-axis robot <NUM> so that the removal assembly <NUM> is conveniently changed and maintained.

Second, in many practical cases, the tape T and the resin R may be completely removed by the first removal operation, and in this case, which is not part of the claimed invention, the second removal step, with the device <NUM>, may be omitted.

<FIG> illustrates a perspective view of a second embodiment of the second removal device.

A plurality of blocks <NUM> are installed in one side of a lower surface of the base <NUM> in a direction perpendicular to the lower surface, and a scraper <NUM> is mounted on a lower surface of each of the blocks <NUM>. The scraper <NUM> is configured to come into contact with most of an upper surface of a casing of the battery module B in left and right directions so that the removal assembly <NUM> moves along a longitudinal side of the casing, i.e., a length direction, so that the removal assembly <NUM> may clean all the material protruding above the upper surface of the casing while moving in parallel on the casing.

An operation, which is not part of the claimed invention, of simultaneously removing the tape T and the resin R by applying the same force while being simultaneously in close contact with the tape T and the resin R may be sequentially performed with respect to a plurality of columns of the tapes T attached along a width direction of the casing, whereby operation time can be further reduced as compared to the method of the present invention.

The block <NUM> and scraper <NUM> of this embodiment may be modified in various ways. According to the present invention, the block <NUM> and scraper <NUM> of the second removal device of the second embodiment may be replaced with the second removal device <NUM> of the first embodiment in the removal assembly <NUM> of the first embodiment.

Next, the transfer shuttle <NUM>, the aligner <NUM>, the blowing module <NUM>, and the cleaning device <NUM> of the present invention will be described with reference to a perspective view of <FIG>.

The transfer shuttle <NUM> of the present invention includes a pair of transfer rails <NUM> which extend long and are adjacent to each other. That is, the transfer shuttle <NUM> has a belt structure similar to the conveyor. The width of the transfer rail <NUM> is manufactured to sufficiently support the length of the battery module B. The transfer module <NUM> places the battery module B on the transfer rail <NUM> so that the battery module B is exactly perpendicular to a moving direction of the transfer rail <NUM>. The placed battery module B is moved forward along the transfer rail <NUM> and supplied to the aligner <NUM>.

The aligner <NUM> of the present invention includes a stopper <NUM> positioned on a front side thereof and a pair of cylinder actuators <NUM> as pressing means each installed on an outer side of each of the transfer rails <NUM>.

The stopper <NUM> is installed at a predetermined position above the platform <NUM> to protrude long in a width direction and prevents the battery module B from moving forward further.

Each of the cylinder actuator <NUM> includes a pressing rod <NUM> that enters an inside of the transfer rail <NUM> or retracts from the transfer rail <NUM> by the driving of a piston inside the body. The pressing rods <NUM> may enter or retract in an inclined direction with respect to the transfer rail <NUM> to press both corners of a side surface or a rear surface of the battery module B from behind the battery module B. The left and right cylinder actuators <NUM> may be connected to each other by a bridge <NUM> to operate simultaneously in real time.

In the present invention, the stopper <NUM> in the front side and two pressing rods <NUM>, which enter the transfer rail <NUM>, should firmly hold both front and rear side surfaces of the battery module B, respectively, to stably fix the position of the battery module B, so that the battery module B does not shake or move finely during the removal operation. Accordingly, a distance between the stopper <NUM> and the pressing rod <NUM> is determined according to the width of the battery module B.

The blowing module <NUM> of the present invention includes a plurality of spray nozzles <NUM> arranged to spray high-pressure air. An opening of the spray nozzle <NUM> is directed upward, and compressed air discharged from the spray nozzle <NUM> flows upward from below at a front surface of the battery module B, so that a portion of the tape T is separated from the casing and directed upward. This operation helps the gripper 54b of the removal assembly <NUM> to grip the tape T.

The cleaning device <NUM> of the present invention includes a cleaner <NUM>, and for example, the cleaner <NUM> is made of a flexible material having a brush or brush structure formed on an outer surface thereof and manufactured in, for example, a roller shape so that resin attached to the knife or scraper that is the second removal device is removed. The removal assembly <NUM> may come into contact with the cleaner <NUM> while reciprocating to remove the resin, or the cleaner <NUM> may rotate in a state in which the removal assembly <NUM> is fixed. In addition, the cleaning device <NUM> may be modified in various ways as long as it achieves the same purpose, for example, the cleaning device <NUM> may be replaced with a nozzle that blows out high-pressure air.

A collector <NUM> is installed in a front side of the cleaning device <NUM> along a height direction of the platform <NUM>. The tape T gripped by the first removal device <NUM> falls and is collected in the collector <NUM>. The collector <NUM> may have a box shape and may be mounted on the platform <NUM> to be replaceable.

Next, a removal operation will be described with mainly reference to the automatic multi-axis robot <NUM> and the removal assembly <NUM> in the automatic removal system <NUM> of the present invention described above with reference to <FIG> and <FIG>.

On the upper surface of the casing of the base module B, the tapes T are attached in three rows along the width direction, and accordingly, three first removal devices <NUM> and three second removal devices <NUM> are mounted. When the MCU of the automatic multi-axis robot <NUM> is driven by a signal of the controller <NUM>, the removal assembly <NUM> may rotate clockwise or counterclockwise or move forward or backward along the y-axis direction, according to the drive arm <NUM>.

The removal assembly <NUM> is placed adjacent to a front upper surface of the battery module B such that the base <NUM> is substantially perpendicular to the upper surface of the battery module, and the grippers 54b are placed adjacent to the tape T to face the tape T, and then, the removal assembly <NUM> rotates to position the tape T in a space between the grippers 54b. When the gripper 54b is switched to the grip position to close the space, the tape T is gripped, and when the removal assembly <NUM> is rotated in the counterclockwise direction, the gripped tape T is picked and lifted from an outer surface of the casing. When the removal assembly <NUM> moves in parallel in a direction A', as the tape T is gradually separated, the tape T and the resin R attached thereto are removed together. The operation of gripping the tape T is more easily performed by the blowing of the spray nozzle <NUM>. This operation state is illustrated in <FIG>.

In this state, when the removal assembly <NUM> moves to the collector <NUM> along a direction B' and then opens the gripper 54b to a non-grip state, the tape T is automatically dropped by gravity and collected in the box.

In addition, in order to completely remove the resin R remaining on the upper surface of the casing, the automatic multi-axis robot <NUM> is driven to rotate the removal assembly <NUM> in a vertical direction, so that the second removal device <NUM> is now positioned to be brought into contact with the upper surface of the casing in a length direction of the battery module B, and then the automatic multi-axis robot <NUM> is driven to linearly move the removal assembly <NUM> along the length direction. This operation state is illustrated in <FIG>. Through this process, the resin R remaining in the casing is removed.

Thereafter, the automatic multi-axis robot <NUM> is driven to rotate the removal assembly <NUM> in the vertical direction, and then, the automatic multi-axis robot <NUM> is driven to move the removal assembly <NUM> again along the direction B' to bring the removal assembly <NUM> into contact with the cleaner <NUM> and remove the resin R attached to the second removal device <NUM>.

Alternatively, unlike <FIG>, a modification is also possible in which, in a state in which the tape T is removed, the removal assembly <NUM> rotates slowly in the clockwise direction in contrast to the previous case and is positioned so that a front end of the knife, which is the second removal device <NUM>, comes into contact with the upper surface of the casing, and then, moves in parallel in the direction B' to remove the remaining resin R.

<FIG> illustrates an actual example in which the upper surface of the casing is completely cleaned using the automatic multi-axis robot <NUM> and the removal assembly <NUM> of the present invention.

According to the present invention, as described above, the tape T and the resin R can be reliably and quickly removed by various methods based on free pivoting and moving motions of the automatic multi-axis robot <NUM>.

When both the tape T and the resin R of the battery module B are removed by the above process, the automatic multi-axis robot <NUM> returns to its initial position. As the pressing rod <NUM> of the cylinder actuator <NUM> moves away from a region of the transfer rail <NUM> by retracting therefrom, the fixed state of the battery module B is released, and the battery module B is moved linearly along the opposite direction by the rotation of the transfer rail <NUM> and is transferred to a place at which the transfer module <NUM> is placed. The transfer module <NUM> operates in an order opposite to that described with reference to <FIG> to place the battery module B on the conveyor <NUM> again, and the battery module B is transferred to a subsequent operation process along the conveyor <NUM>.

An example of the finishing process has been described above, and various modifications are possible, for example, the battery module B from which the tape T and the resin R are removed is directly moved from the aligner <NUM> to an adjacent work bench using an automatic arm (not shown).

Claim 1:
An automatic removal system (<NUM>) for automatically removing a tape (T) and a resin (R) exposed to an outside of a battery module (B), the system (<NUM>) comprising:
a removal assembly (<NUM>) including a removal device (<NUM>, <NUM>) for removing the tape (T) and the resin (R); and
an automatic multi-axis robot (<NUM>) coupled to the removal assembly (<NUM>) and configured to drive the removal assembly (<NUM>) to remove the tape (T) and the resin (R) of the battery module (B),
wherein the removal assembly (<NUM>) includes a first removal device (<NUM>) for removing the tape (T) and the resin (R) attached to the tape (T),
wherein the removal assembly (<NUM>) further includes a second removal device (<NUM>) for removing the resin (R) remaining on the battery module (B) left by the first removal device (<NUM>),
characterized in that
the first removal device (<NUM>) includes rods (54a) arranged side by side along one side of a base (<NUM>) of the removal assembly (<NUM>) and each of the rods (54a) extending downward, and a gripper (54b) integrally formed at a front end of each of the rods (54a), and
the second removal device (<NUM>) includes a support bracket (<NUM>) or block (<NUM>) formed on a second side of the removal device opposite to a first side in which the first removal device (<NUM>) is arranged, and a knife or scraper (<NUM>) installed on the support bracket (<NUM>) or block (<NUM>) to remove the resin (R).