e-Mobility and Battery Pack Assembly The power behind your assembly line Vision sensors Optical sensors Ultrasonic sensors Inductive sensors

Smart solutions for the entire production process Our e-Mobility and battery assembly solutions Efforts to reduce fossil fuel consumption are leading to a rapid rise in electromobility. Electrically powered cars, bicycles and even scooters are becoming increasingly popular. These modes of transportation all require battery power, which means the market for battery pack manufacturing is growing alongside the e-mobility sector. As with any assembly line, there are various challenges in battery pack manufacturing, especially with automated processes in production. Sensors, such as vision or distance...

If a part is missing, assembled in the wrong way, or does not meet the specifications, it will adversely affect the final product. As the battery pack is heavily sealed, it will incur a significant cost to put the problem right, so inspection by a vision sensor is extremely important when it comes to critical electrical connections or protective parts. Identification of parts and components is important to ensure gapless traceability and avoid process downtime. Sensors must be able to read plain text, identify different types of barcodes and read printed or directly marked data matrix codes reliably,...

Automation requirements for battery assembly lines Overview of the application areas As with any assembly line, the process of manufacturing battery packs faces challenges, particularly when using automated production techniques. At each station, a sensor represents an important component of process automation – whether in the context of object inspections, reading individual component serial numbers before they are assembled, or guiding robots. Hardware and software solutions are required for three key applications – identification, positioning and inspection. It is important that all components...

Last but not least, vision inspection is extremely important when it comes to critical electrical connections or protective parts. If a part is missing, assembled in the wrong way, or does not meet the specifications, it will adversely affect the final product and lead to expensive costs, as the battery pack is heavily sealed. The application challenges and requirements in battery pack assembly are very similar to those in car body construction. SensoPart is well versed in automotive manufacturing, so this expertise can easily be translated to the battery pack assembly line. It also means that...

Hardware and software solutions for each stage of the assembly line A sensor por tfolio covering every impor tant task These include optical sensors such as: Switching and measuring sensors are the standard solution in factory automation. SensoPart offers the right sensor for almost every conceivable application: The product range offers a comprehensive selection of different sizes, ranges and operating principles. From the smallest sensors in subminiature format for confined installation conditions to sensors in compact format for long sensing ranges, the entire portfolio offers excellent performance...

Our portfolio of vision sensors includes: Here, the VISOR® family offers an unbeatable advantage: regardless of which VISOR® type is integrated, all VISOR® products combine the same software connection and configuration as well as the same mechanical integration. This significantly reduces the installation and training effort for control engineers, robot integrators and mechanical construction, as well as the maintenance team, when the assembly line is working. All sensors offer industrial standards such as IO-Link or Profinet, further simplifying sensor integration to the robots of leading manufacturers....

Reading the delivery note Identification The task: In the first step, it is important to know which components are installed in a battery pack. This information is collected in the delivery note attached to the transport box, and is read by a sensor. The contents can consist of one-dimensional barcodes, two-dimensional data matrix codes or even plain text. This information is then transmitted to the higher-level control system to guarantee the traceability of the installed products. The challenge: In order to keep the required logistics area clear, the sensor often has to be mounted at a certain...

Our solution: The code readers of the VISOR® series are available in different optical and illumination variants, so that the right hardware variant is available depending on the given installation situation. With optional accessories, e.g. spotlights, the delivery notes can be well illuminated even from a great distance, so that the contents can be read reliably even in changing ambient light. With the associated software, it is very easy to store different label types as identification jobs. In addition, it is possible to flexibly select between barcode, datacode and OCR in each of these jobs....

Position detection of the lower housing in the material container Positioning The task: The base of a battery pack is the housing bottom part, which is first removed from a material container by a gantry or articulatedarm robot. For his purpose, it is necessary to determine the position of the component without contact. The challenge: The housing bottom parts are transported to the removal station in material containers, resulting in a certain position inaccuracy of the components. For a precise gripping process, sensors determine the exact position of the housing bottom parts. The size of such...

Our solution: With the VISOR® Robotic, the exact position of the housing bottom parts is determined and transmitted to the controller in robot coordinates. Due to the compact and robust design of the VISOR®, it can be integrated into the robot gripper. With the help of standardized calibration plates, the image coordinates can be converted into world coordinates. Due to the size of the battery modules, the X/Y coordinates are determined on the basis of two component features, which are then calculated into a central object coordinate. This results in high accuracy for a reliable gripping process....