Patent Description:
As the demand for electric vehicles increases worldwide, there is also an increasing demand for facilities related to batteries mounted in the electric vehicles.

The electric vehicle uses, as a main power source, a battery in which a plurality of secondary battery cells, which is chargeable and dischargeable, is integrated into a single pack. Therefore, the electric vehicle releases no exhaust gas and causes very little noise.

In the case of the battery applied to the electric vehicle, a battery module assembly is configured by stacking a plurality of battery cells, and a battery pack assembly is configured by electrically connecting a plurality of battery module assemblies and mounted in the vehicle.

Various electrical components (e.g., a PCB, a BMS, a busbar, a clamp, and the like) are mounted in the battery pack assembly, and the electrical components are coupled to a battery module through a welding process.

In the welding process in the related art, welding facilities are installed for respective portions where the electrical components are welded to the battery pack assemblies along a conveyor by which the battery pack assemblies are conveyed in one direction (or, disposed in series). For example, <CIT> discloses a lithium battery ear ultrasonic welding machine comprising a conveyor belt, a turning mechanism, a loading robot, a blanking robot and four ultrasonic welding machines.

Therefore, because expensive oscillators need to be provided for the respective welding facilities, there is a problem in that a large amount of costs is required to establish the welding facilities.

In addition, the battery pack assemblies are conveyed in series along the conveyor. Therefore, when one of the plurality of welding facilities disposed along the conveyor is broken down or needs to be cleaned, operations of all the welding facilities disposed along the conveyor need to be stopped.

The above information disclosed in this Background section is only for enhancement of understanding of the background of the disclosure, and therefore it may contain information that does not form the prior art that is already known in this country to a person of ordinary skill in the art.

In one aspect, the present invention has been made in an effort to provide a welding system according to claim and a welding method according to claim <NUM> using the same, which are capable of reducing a cycle time of a welding process and increasing an operation rate.

An embodiment of the present invention provides a welding system including:
a main conveyor configured to convey a battery palette on which a battery module assembly is mounted; at least two auxiliary conveyors disposed in parallel with the main conveyor; a loading-unloading module configured to transfer the battery palette to the auxiliary conveyor and/or transfer the battery palette from the auxiliary conveyor to the main conveyor; clamping jigs on which the battery palettes are seated by the loading-unloading module so that a preset welding process is performed on the auxiliary conveyors; and at least two welding robots configured to weld the battery module assemblies seated on the at least two auxiliary conveyors.

The loading-unloading module may be configured to transfer the battery palette, which is conveyed along the main conveyor, to the auxiliary conveyor and transfer the battery palette, which is completely subjected to the preset welding process, from the auxiliary conveyor to the main conveyor.

The auxiliary conveyor may include: a drive unit configured to generate power; a lead screw connected to a rotary shaft of the drive unit and gear-coupled to the battery palette; and an LM guide configured to guide the clamping jig.

The clamping jig may include: a support plate on which the battery module is seated; a first pressing jig configured to press, in a first direction, a welding object against the battery module assembly seated on the support plate; a second pressing jig configured to press, in a second direction, another welding object against the battery module assembly seated on the support plate; and a back-up jig configured to fix, in a third direction, the battery palette seated on the support plate.

The support plate may have a support pad and a support protrusion that set a direction and a position of the battery palette.

The welding system according to the embodiment of the present invention may further include a suction module provided on the clamping jig and configured to remove fume or spatters produced by the welding process.

The welding system according to the embodiment of the present invention may further include a saltwater container configured to extinguish a fire on the battery module assembly by means of the loading-unloading module when a temperature of the battery module assembly is a preset temperature or higher or when a fire occurs on the battery module assembly.

When any one of the at least two auxiliary conveyors is abnormal, a welding process may be performed on the battery module assembly by the other auxiliary conveyor.

The two welding robots may perform the welding process on the battery module assembly loaded onto the other auxiliary conveyor.

When any one of the at least two welding robots is abnormal, a welding process may be performed on the battery module assembly by the other welding robot.

In some embodiments, the at least two welding robots may comprise an oscillator configured to emit laser beams.

In some embodiments, the at least two welding robots may comprise a chiller configured to cool the oscillator.

In some embodiments, the welding system may further comprise a detection unit configured to detect a state information of the battery module assembly, a state information of the welder, a state information of the welding robot, and a state information of the auxiliary conveyor. The welding system may further comprise a controller, and the state information detected by the detection unit may be transmitted to the controller.

Another embodiment of the present invention provides a welding method using the welding system according to claim <NUM>, the welding method including: determining whether the welding robot is normal; determining whether the auxiliary conveyor is normal; and welding the battery module assembly by using the welding robot and the auxiliary conveyor based on a state of the welding robot and a state of the auxiliary conveyor.

When the at least two welding robots and the at least two auxiliary conveyors are normal, the battery module assemblies on the at least two auxiliary conveyors may be welded.

When the at least two welding robots are normal and any one of the at least two auxiliary conveyors is abnormal, the normal two welding robots may weld the battery module assemblies on the normal auxiliary conveyor.

The welding method according to the embodiment of the present invention may further include determining whether the auxiliary conveyor disposed adjacent to the normal welding robot is normal when any one of the at least two welding robots is abnormal.

When the auxiliary conveyor disposed adjacent to the normal welding robot is normal, the normal welding robot may weld the battery module assembly on the normal auxiliary conveyor.

According to the welding system according to the embodiment of the present invention described above, the at least two auxiliary conveyors are disposed in parallel with the main conveyor. Therefore, even though any one auxiliary conveyor is abnormal, the remaining auxiliary conveyors may perform the welding process. Therefore, it is possible to increase the operation rate of the entire system for the welding process.

As discussed, the method and system suitably include use of a controller or processer.

Because the drawings are provided for reference to describe exemplary embodiments of the present invention, the scope of the invention should not be construed as being limited to the accompanying drawings.

It is understood that the term "vehicle" or "vehicular" or other similar term as used herein is inclusive of motor vehicles in general such as passenger automobiles including sports utility vehicles (SUV), buses, trucks, various commercial vehicles, watercraft including a variety of boats and ships, aircraft, and the like, and includes hybrid vehicles, electric vehicles, plug-in hybrid electric vehicles, hydrogen-powered vehicles and other alternative fuel vehicles (e.g. fuels derived from resources other than petroleum). As referred to herein, a hybrid vehicle is a vehicle that has two or more sources of power, for example both gasoline-powered and electric-powered vehicles.

These terms are merely intended to distinguish one component from another component, and the terms do not limit the nature, sequence or order of the constituent components. Throughout the specification, unless explicitly described to the contrary, the word "comprise" and variations such as "comprises" or "comprising" will be understood to imply the inclusion of stated elements but not the exclusion of any other elements. In addition, the terms "unit", "-er", "-or", and "module" described in the specification mean units for processing at least one function and operation, and can be implemented by hardware components or software components and combinations thereof.

Although exemplary embodiment is described as using a plurality of units to perform the exemplary process, it is understood that the exemplary processes may also be performed by one or plurality of modules. Additionally, it is understood that the term controller/control unit refers to a hardware device that includes a memory and a processor and is specifically programmed to execute the processes described herein. The memory is configured to store the modules and the processor is specifically configured to execute said modules to perform one or more processes which are described further below.

Further, the control logic of the present disclosure may be embodied as non-transitory computer readable media on a computer readable medium containing executable program instructions executed by a processor, controller or the like. Examples of computer readable media include, but are not limited to, ROM, RAM, compact disc (CD)-ROMs, magnetic tapes, floppy disks, flash drives, smart cards and optical data storage devices. The computer readable medium can also be distributed in network coupled computer systems so that the computer readable media is stored and executed in a distributed fashion, e.g., by a telematics server or a Controller Area Network (CAN).

Embodiments of the present invention will be described in detail with reference to the accompanying drawings so that those with ordinary skill in the art to which the present disclosure pertains may easily carry out the embodiments. However, the present invention may be implemented in various different ways and is not limited to the embodiments described herein.

A part irrelevant to the description will be omitted to clearly describe the present invention, and the same or similar constituent elements will be designated by the same reference numerals throughout the specification.

In addition, the size and thickness of each component illustrated in the drawings are arbitrarily shown for ease of description, but the present disclosure is not limited thereto. In order to clearly describe several portions and regions, thicknesses thereof are enlarged.

Hereinafter, a welding system according to an embodiment of the present invention will be described in detail with reference to the accompanying drawings.

<FIG> is a perspective view illustrating a configuration of a welding system according to an embodiment of the present invention.

Further, <FIG> is a block diagram of the welding system according to the embodiment of the present invention.

As illustrated in <FIG> and <FIG>, a welding system according to an embodiment of the present invention may include: a main conveyor <NUM> configured to convey a battery module assembly (BMA); at least two auxiliary conveyors <NUM> disposed in parallel with the main conveyor <NUM>; a loading-unloading module <NUM> configured to transfer the battery module assembly between the main conveyor <NUM> and the auxiliary conveyor <NUM>; clamping jigs <NUM> configured to clamp and/or unclamp the battery module assembly; and at least two welding robots <NUM> configured to weld the battery module assembly.

The main conveyor <NUM> conveys the battery module assembly in a preset direction so that preset working processes (e.g., a process of stacking battery cells, a process of assembling the battery cells, a welding process, and the like) are performed. In this case, the battery module assembly is conveyed by the main conveyor <NUM> in a state in which the battery module assembly is mounted on a battery palette <NUM>. Hereinafter, for the convenience of description, the battery palette <NUM> may include a state in which the battery module assembly is mounted on the battery palette <NUM>.

The battery palette <NUM> is provided in the form of a plate on which the battery pack assembly <NUM> is seated. The battery palette <NUM> is seated on support pads <NUM> of a support plate <NUM> of the clamping jig <NUM> which will be described below. Two support holes <NUM> are formed in diagonal edge portions of the battery palette <NUM>, and support protrusions <NUM> of the support plate <NUM> of the clamping jig <NUM>, which will be described below, are inserted into the support holes <NUM>. Back-up holes <NUM> are formed in a lateral surface of the battery palette <NUM>, and back-up jigs <NUM> to be described below are inserted into the back-up holes <NUM>.

The main conveyor <NUM> may include a belt operated by a main drive unit <NUM> (e.g., an electric motor) (not illustrated).

The at least two auxiliary conveyors <NUM> are provided in parallel with a conveyance direction of the battery module assembly mounted on the main conveyor <NUM>. The two auxiliary conveyors <NUM> include a first auxiliary conveyor <NUM> and a second auxiliary conveyor <NUM>. The auxiliary conveyor <NUM> relatively close to the main conveyor <NUM> is referred to as the first auxiliary conveyor <NUM>, and the auxiliary conveyor <NUM> relatively distant from the main conveyor <NUM> is referred to as the second auxiliary conveyor <NUM>. In the embodiment of the present disclosure, the example will be described in which the two auxiliary conveyors <NUM> are provided in parallel with the main conveyor <NUM>. However, the protection scope of the present invention is not limited thereto. A detailed configuration of the auxiliary conveyor <NUM> will be described below.

The loading-unloading module <NUM> transfers the battery palette <NUM>, which is conveyed along the main conveyor <NUM>, to the auxiliary conveyor <NUM> and/or transfers the battery palette <NUM> from the auxiliary conveyor <NUM> to the main conveyor <NUM>. For example, the loading-unloading module <NUM> transfers the battery palette <NUM>, on which the battery module assembly, which is not subjected to the welding process, is mounted, from the main conveyor <NUM> to the auxiliary conveyor <NUM> or transfers the battery palette <NUM>, on which the battery module assembly, which has been completely subjected to the welding process, is mounted, from the auxiliary conveyor <NUM> to the main conveyor <NUM>. To this end, the loading-unloading module <NUM> may be implemented as a two-axis orthogonal robot. That is, the loading-unloading module <NUM> may operate in the conveyance direction of the main conveyor <NUM> and a direction perpendicular to the conveyance direction of the main conveyor <NUM>.

The clamping jig <NUM> clamps (or fixes) the battery palette <NUM> mounted on the auxiliary conveyor <NUM>. That is, the battery palette <NUM>, which is transferred from the main conveyor <NUM> to the auxiliary conveyor <NUM> by the loading-unloading module <NUM>, is seated on the clamping jig <NUM> so that the preset welding process is performed. A detailed configuration of the clamping jig <NUM> will be described below. The clamping jig <NUM> may be conveyed along the auxiliary conveyor <NUM>, as necessary.

The at least two welding robots <NUM> are provided adjacent to the two auxiliary conveyors <NUM>. The two welding robots <NUM> include a first welding robot <NUM> disposed adjacent to the first auxiliary conveyor <NUM>, and a second welding robot <NUM> disposed adjacent to the second auxiliary conveyor <NUM>. In the embodiment of the present disclosure, the two auxiliary conveyors <NUM> are disposed adjacent to each other in parallel, the first welding robot <NUM> is disposed adjacent to the first auxiliary conveyor <NUM>, and the second welding robot <NUM> is disposed adjacent to the second auxiliary conveyor.

A welder <NUM> mounted at an end of the welding robot <NUM> welds the battery module assembly mounted on the battery palette <NUM> seated on the clamping jig <NUM>. To this end, the welding robot <NUM> may be implemented as a six-axis articulated robot. The welding robot <NUM> may be implemented as the six-axis articulated robot and weld a front surface, a rear surface, a left surface, and a right surface of the battery module assembly. Further, the welder <NUM> may include an oscillator <NUM> configured to emit laser beams, and a chiller <NUM> configured to cool the oscillator <NUM>.

The welding system according to the embodiment of the present invention may include a controller <NUM> configured to control operations of the main conveyor <NUM>, the auxiliary conveyors <NUM>, the loading-unloading module <NUM>, the clamping jigs <NUM>, and the welding robots <NUM>.

The controller <NUM> may be implemented as a manufacturing execution system (MES). The controller <NUM> collects information on states (e.g., welding portions, positions of the battery module assemblies, and the like) of the battery module assemblies, information on states (e.g., normal or abnormal states) of the welders <NUM>, information on states (e.g., normal or abnormal states of the welding robots <NUM>) of the welding robots <NUM>, and information on states (e.g., normal states of the auxiliary conveyors <NUM>, stand-by states for facility inspection, or abnormal states) of the auxiliary conveyors <NUM>. The controller <NUM> instructs the welding robot <NUM> to perform the welding process on the battery module assembly based on the collected state information. The controller <NUM> may control the main conveyor <NUM>, the auxiliary conveyors <NUM>, the loading-unloading module <NUM>, the clamping jigs <NUM>, and the welding robots <NUM> by using a programmable logic controller (PLC).

To this end, the welding system according to the embodiment of the present disclosure invention may include a detection unit <NUM> configured to detect the state information of the battery module assembly, the state information of the welder <NUM>, the state information of the welding robot <NUM>, and the state information of the auxiliary conveyor <NUM>. The state information detected by the detection unit <NUM> is transmitted to the controller <NUM>.

The state information of the battery module assembly includes information on the welding portion of the battery module assembly. The state information of the welders <NUM> includes normal operating states and abnormal operating states of the plurality of welders <NUM>. The state information of the welding robot <NUM> includes normal operating states and abnormal operating states of the plurality of welding robots <NUM>. The state information of the auxiliary conveyors <NUM> include normal operating states and abnormal operating states of the plurality of auxiliary conveyors <NUM>.

The controller <NUM> may include one or more processors configured to be operated by a preset program, and the preset program performs respective steps of a method of controlling a vehicle having a motor according to the embodiment of the present disclosure.

The welding system according to the embodiment of the present invention may include a saltwater container <NUM> configured to extinguish a fire on the battery module assembly due to an abnormal situation (e.g., heating of the battery module assembly and/or a fire on the battery module assembly) by means of the loading-unloading module <NUM>.

Hereinafter, the configuration of the auxiliary conveyor <NUM> according to the embodiment of the present invention will be described in detail with reference to the accompanying drawings.

<FIG> is a perspective view illustrating the configuration of the auxiliary conveyor according to the embodiment of the present invention.

Referring to <FIG>, the auxiliary conveyor <NUM> includes the drive unit <NUM> configured to generate power, a lead screw <NUM> connected to a rotary shaft of the drive unit <NUM>, and a pair of LM guides <NUM> configured to guide the clamping jig <NUM>.

The drive unit <NUM> may be a servo motor for generating power and disposed between the pair of LM guides <NUM>.

The lead screw <NUM> (or a ball screw) may be integrally connected to the rotary shaft of the drive unit <NUM> and screw-coupled to a movable plate <NUM> (to be described below) of the clamping jig <NUM>.

When the lead screw <NUM> is rotated by power of the drive unit <NUM>, the clamping jig <NUM> screw-coupled to the lead screw <NUM> moves in a forward/rearward direction in an axial direction of the lead screw <NUM>.

The pair of LM guides <NUM> is provided to guide the movement of the movable plate <NUM> of the clamping jig <NUM>.

Next, the configuration of the clamping jig <NUM> according to the embodiment of the present invention will be described in detail with reference to the accompanying drawings.

<FIG> and <FIG> are perspective views illustrating the configuration of the clamping jig according to the embodiment of the present invention. For the convenience of understanding, <FIG> illustrates the clamping jig <NUM> from which some constituent elements are eliminated.

Referring to <FIG> and <FIG>, the clamping jig <NUM> includes the movable plate <NUM>, the support plate <NUM> disposed above the movable plate <NUM>, a pair of first pressing jigs <NUM> disposed to be movable in a forward/rearward direction of the support plate <NUM>, the back-up jigs <NUM> disposed on a lateral surface of the support plate <NUM> and configured to be movable in an upward/downward direction, and a pair of second pressing jigs <NUM> disposed to be movable in a leftward/rightward direction of the support plate <NUM>.

A central lower portion of the movable plate <NUM> is screw-coupled to the lead screw <NUM> of the auxiliary conveyor <NUM>. When power is generated by the drive unit <NUM>, the movable plate <NUM> is moved in the movement direction of the auxiliary conveyor <NUM> (e.g., in the forward/rearward direction) by the rotation of the lead screw <NUM>. In this case, because lower portions of two opposite sides of the movable plate are guided by the LM guides <NUM>, the stable movement of the movable plate <NUM> in the forward/rearward direction is ensured.

The support plate <NUM> disposed above the movable plate <NUM> is a portion on which the battery palette <NUM>, on which the battery module assembly, is mounted is seated. A plurality of support pads <NUM> and a plurality of support protrusions <NUM> are formed on the upper surface of the support plate <NUM> to position the battery palette <NUM> at the accurate position.

A bottom surface of the battery palette <NUM> is seated on the plurality of support pads <NUM> formed on the upper surface of the support plate <NUM>, such that a position of the battery palette <NUM> in a height direction may be accurately set. In the embodiment of the present invention, four support pads <NUM> may be respectively formed at edges of the support plate <NUM>.

The support protrusion <NUM> may protrude upward from the support pad <NUM> formed on the support plate <NUM>. In the embodiment of the present invention, a pair of support protrusions <NUM> may be formed in a diagonal direction of the support plate <NUM>. The support holes <NUM> (or support grooves) (not illustrated) corresponding to the support protrusions <NUM> may be formed in the battery palette <NUM>.

The pair of first pressing jigs <NUM> presses, in a first direction (e.g., the forward/rearward direction), a welding object (e.g., front and rear clamping devices for welding busbars and the like to front and rear sides of the battery module assembly) against the battery module assembly on the battery palette <NUM> seated on the support plate <NUM>. To this end, the pair of first pressing jigs <NUM> is movably provided on an upper portion of the movable plate <NUM> (or disposed at front and rear sides of the support plate <NUM>). The pair of first pressing jigs <NUM> may be moved in the forward/rearward direction by power generated by a first cylinder. The first cylinder may be implemented as a hydraulic cylinder or a pneumatic cylinder.

The pair of second pressing jigs <NUM> presses, in a second direction (e.g., the leftward/rightward direction), a welding object (e.g., left and right clamping devices for welding busbars and the like to left and right sides of the battery module assembly) against the battery module assembly of the battery palette <NUM> seated on the support plate <NUM>. To this end, the pair of second pressing jigs <NUM> is movably provided on the upper portion of the movable plate <NUM> (or disposed at the front and rear sides of the support plate <NUM>). The pair of second pressing jigs <NUM> may be moved in the leftward/rightward direction by power generated by a second cylinder. The second cylinder may be implemented as a hydraulic cylinder or a pneumatic cylinder.

The back-up jigs <NUM> fix the battery palette <NUM> to stably restrain the battery palette <NUM> seated on the support plate <NUM>. To this end, the back-up jigs <NUM> are provided on the movable plate <NUM> and configured to be movable in the upward/downward direction. The back-up jigs <NUM> may be moved in the upward/downward direction by power generated by a back-up cylinder. The back-up cylinder may be implemented as a hydraulic cylinder or a pneumatic cylinder. The back-up holes <NUM> corresponding to the back-up jigs <NUM> are formed in the battery palette <NUM>, and the back-up jigs <NUM> are inserted into the back-up holes <NUM>, such that the battery palette <NUM> may be fixed.

Meanwhile, a suction module <NUM> may be provided on the clamping jig <NUM> and suck foreign substances (e.g., fume and/or spatters) produced during the welding process. Because the suction module <NUM> sucks foreign substances produced during the welding process, it is possible to reduce the time required to clean and/or repair the auxiliary conveyor <NUM> and the clamping jig <NUM>.

<FIG> are views for explaining operating states of the clamping jig according to the embodiment of the present invention.

For the convenience of understanding, <FIG> illustrates a state in which the second pressing jig <NUM> and the back-up jig <NUM> are eliminated, and <FIG> illustrates a state in which the first pressing jig <NUM> and the second pressing jig <NUM> are eliminated.

Referring to <FIG>, the battery palette <NUM> is seated on the support plate <NUM> of the clamping jig <NUM> by the loading-unloading module <NUM>. In this case, a lower surface of the battery palette <NUM> is seated on the support pad <NUM> of the support plate <NUM>. Therefore, the position of the battery palette <NUM> in the upward/downward direction is accurately set. Further, the support protrusion <NUM> of the support plate <NUM> is inserted into the support hole <NUM> of the battery palette <NUM> when the battery palette <NUM> is seated on the support plate <NUM>. Therefore, the position of the battery palette <NUM> in the forward/rearward direction and the leftward/rightward direction is accurately set (see <FIG>).

When the battery palette <NUM> is accurately seated on the support plate <NUM>, the welding object is supported on the front and rear surfaces of the battery module assembly by the first pressing jigs <NUM> (see <FIG>). Further, the battery palette <NUM> is fixedly supported on the support plate <NUM> by the back-up jigs <NUM> (see <FIG>). Thereafter, the welding object is supported on the left and right surfaces of the battery module assembly by the second pressing jigs <NUM> (see <FIG>).

Because the welding object is clamped in a lump on the welding portion of the battery module assembly by the clamping jig <NUM> as described above, it is possible to reduce the cycle time of the welding process and ensure uniform welding quality.

Hereinafter, a method of welding a battery module assembly according to the embodiment of the present invention will be described in detail with reference to the accompanying drawings.

<FIG> is a flowchart for explaining a method of welding a battery module assembly according to the embodiment of the present invention.

Referring to <FIG>, the controller <NUM> uses the detection unit <NUM> and collects the state information of the battery module assembly, the state information of the welder <NUM>, the state information of the welding robot <NUM>, and the state information of the auxiliary conveyor <NUM> (S10).

The controller <NUM> determines whether the welders <NUM> and the welding robots <NUM> provided on the auxiliary conveyors <NUM> are normal (S20).

When the welders <NUM> and the welding robots <NUM> are normal in step S20, the controller <NUM> instructs the two welding robots <NUM> to perform welding on the battery module assemblies (S21).

The controller <NUM> determines whether the two auxiliary conveyors <NUM> are normal (S30).

When both the two auxiliary conveyors <NUM> are normal in step S30, the controller <NUM> performs welding on the battery module assemblies on both the auxiliary conveyors <NUM> by using the normal welders <NUM> and the normal welding robots <NUM> (S31).

That is, the controller <NUM> allows the loading-unloading module <NUM> to seat the battery palettes <NUM>, on which the battery module assemblies being conveyed along the main conveyor <NUM> are seated, on the clamping jigs <NUM> of the auxiliary conveyors <NUM>. The controller <NUM> allows the clamping jig <NUM> to temporarily support the welding object by pressing the welding object against the welding portion of the battery module assembly. Further, the controller <NUM> allows the two welding robots <NUM> to perform welding on the battery module assemblies seated on the clamping jigs <NUM> of the auxiliary conveyors <NUM>. In this case, because the welding is performed on the battery module assemblies by the two welding robots <NUM>, it is possible to reduce the cycle time of the welding process.

In step S30, when any one of the two auxiliary conveyors <NUM> (e.g., the first auxiliary conveyor <NUM>) is abnormal, the controller <NUM> performs welding on the battery module assembly on the normal auxiliary conveyor <NUM> (S33).

That is, the controller <NUM> allows the loading-unloading module <NUM> to seat the battery palettes <NUM>, on which the battery module assemblies being conveyed along the main conveyor <NUM> are seated, on the clamping jig <NUM> of the other auxiliary conveyor <NUM> (e.g., the second auxiliary conveyor <NUM>). The controller <NUM> allows the clamping jig <NUM> to temporarily support the welding object by pressing the welding object against the welding portion of the battery module assembly. The controller <NUM> allows the welding robot <NUM> to weld the welding object to the battery module assembly seated on the clamping jig <NUM> of the auxiliary conveyor <NUM>.

As described above, when any one of the two auxiliary conveyors <NUM> is being broken down or repaired and thus in an abnormal state, the other auxiliary conveyor <NUM> performs the welding process on the battery module assembly, which makes it possible to increase an operation rate of a welding line.

Meanwhile, when any one of the two welding robots <NUM> or any one of the two welders <NUM> is abnormal in step S20, the controller <NUM> determines whether the auxiliary conveyor <NUM> disposed adjacent to the other welding robot <NUM> is normal (S40).

If the auxiliary conveyor <NUM> disposed adjacent to the other welding robot <NUM> is abnormal, the controller <NUM> stops the process without performing the welding process on the battery module assembly.

When the auxiliary conveyor <NUM> disposed adjacent to the other welding robot <NUM> is normal in step S40, the controller <NUM> performs welding on the battery module assembly on the auxiliary conveyor <NUM> disposed adjacent to the normal welder <NUM> and the normal welding robot <NUM> (S41).

That is, the controller <NUM> allows the loading-unloading module <NUM> to seat the battery palettes <NUM>, on which the battery module assemblies being conveyed along the main conveyor <NUM> are seated, on the clamping jig <NUM> of the auxiliary conveyor <NUM> disposed adjacent to the normal welding robot <NUM>. The controller <NUM> allows the clamping jig <NUM> to temporarily support the welding object by pressing the welding object against the welding portion of the battery module assembly. Further, the controller <NUM> allows the single welding robot <NUM> to perform welding on the battery module assembly seated on the clamping jig <NUM> of the auxiliary conveyor <NUM>.

According to the welding system and the welding method using the same according to the embodiment of the present invention described above, the welding objects are welded to the battery module assemblies by the two auxiliary conveyors <NUM> disposed in parallel and the two welding robots <NUM> disposed adjacent to the two auxiliary conveyors <NUM>. Therefore, it is possible to reduce the cycle time required for the process of welding the battery module assembly.

In addition, when any one of the two auxiliary conveyors <NUM> is abnormal (e.g., when the auxiliary conveyor is being broken down, repaired, and/or cleaned), the welding process may be performed on the battery module assembly by the other auxiliary conveyor <NUM>, which makes it possible to increase an operation rate of the entire welding system.

Likewise, when any one of the two welding robots <NUM> (or the two welders <NUM>) is abnormal (e.g., when the welding robot <NUM> is broken down), the welding process may be performed on the battery module assembly by the other welding robot <NUM>, which makes it possible to increase an operation rate of the entire welding system.

Because the welding object is supported in a lump on the battery module assembly by the clamping jig <NUM>, it is possible to reduce the cycle time of the welding process and ensure uniform welding quality.

While the example has been above described in which the welding system according to the embodiment of the present invention is applied to the process of welding the battery module assembly, the protection scope of the present invention is not limited thereto. As necessary, the welding system according to the embodiment of the present invention may be applied to a process of welding a stator of a hairpin motor.

Claim 1:
A welding system comprising:
a main conveyor (<NUM>) configured to convey a battery palette (<NUM>) on which a battery module assembly (BMA) is mounted;
at least two auxiliary conveyors (<NUM>) disposed in parallel with the main conveyor (<NUM>);
a loading-unloading module (<NUM>) configured to transfer the battery palette (<NUM>) to the auxiliary conveyor (<NUM>) and/or transfer the battery palette (<NUM>) from the auxiliary conveyor (<NUM>) to the main conveyor (<NUM>);
clamping jigs (<NUM>) on which the battery palettes (<NUM>) are seated whereby a welding process can be performed on the auxiliary conveyors (<NUM>); and
at least two welding robots (<NUM>) configured to weld the battery module assemblies (BMA) seated on the at least two auxiliary conveyors (<NUM>).