Abstract: A battery pack assembly and a method of making the same. The method includes using lifters with a cammed conveyor delivery mechanism to facilitate edgewise stacking of generally planar battery cells. The lifter spacing and cam profile are designed in such a way as to orient individual battery cell tabs and cooling fin assemblies to keep them close together but without applying significant forces to the stackable components. Combining conveyor streams allows components to be processed in parallel and sequenced correctly onto a single conveyor. Use of lifter integrated conveyor belt with cams and guides for individual battery cell orientation and sequencing promotes high speed assembly without a need to change component directions. The use of high-speed component delivery high is compatible with allowing more component placement variation, while the edgewise orientation of the components being assembled permits the use of small manufacturing footprints.

Abstract: A method includes the following steps: actuating a robotic arm to perform an action at a start position; moving the robotic arm from the start position toward a first position; determining from a vision process method if a first part from the first position will be ready to be subjected to a first action by the robotic arm once the robotic arm reaches the first position; commencing the execution of the visual processing method for determining the position deviation of the second part from the second position and the readiness of the second part to be subjected to a second action by the robotic arm once the robotic arm reaches the second position; and performing a first action on the first part using the robotic arm with the position deviation of the first part from the first position predetermined by the vision process method.

Abstract: A method for generating a candidate assembly system layout for an assembled product includes inputting a bill of materials including a list of components for the assembled product and determining a plurality of assembly patterns for the assembled product including a plurality of intermediate assemblies and sub-assemblies. A basic task layout is determined that includes assembly tasks for assembling the assembled product based upon a selected one of the assembly patterns. A whole task layout is determined based upon the basic task layout for the selected assembly pattern. Candidate assembly machines are selected for the whole task layout, and zoning constraints are identified for the candidate assembly machines related to assembly tasks. A candidate assembly system layout is generated based upon the whole task layout, the selected candidate assembly machines and the zoning constraints, from which a simulation model of a candidate assembly system is generated.

Abstract: A system and method for stacking battery cells or related assembled components. Generally planar, rectangular (prismatic-shaped) battery cells are moved from an as-received generally vertical stacking orientation to a generally horizontal stacking orientation without the need for robotic pick-and-place equipment. The system includes numerous conveyor belts that work in cooperation with one another to deliver, rotate and stack the cells or their affiliated assemblies. The belts are outfitted with components to facilitate the cell transport and rotation. The coordinated movement between the belts and the components promote the orderly transport and rotation of the cells from a substantially vertical stacking orientation into a substantially horizontal stacking orientation.

Abstract: A battery pack assembly and a method of making the same. The method includes using lifters with a cammed conveyor delivery mechanism to facilitate edgewise stacking of generally planar battery cells. The lifter spacing and cam profile are designed in such a way as to orient individual battery cell tabs and cooling fin assemblies to keep them close together but without applying significant forces to the stackable components. Combining conveyor streams allows components to be processed in parallel and sequenced correctly onto a single conveyor. Use of lifter integrated conveyor belt with cams and guides for individual battery cell orientation and sequencing promotes high speed assembly without a need to change component directions. The use of high-speed component delivery high is compatible with allowing more component placement variation, while the edgewise orientation of the components being assembled permits the use of small manufacturing footprints.

Abstract: A battery pack assembly and a method of making the same. The method includes using lifters with a cammed conveyor delivery mechanism to facilitate edgewise stacking of generally planar battery cells. The lifter spacing and cam profile are designed in such a way as to orient individual battery cell tabs and cooling fin assemblies to keep them close together but without applying significant forces to the stackable components. Combining conveyor streams allows components to be processed in parallel and sequenced correctly onto a single conveyor. Use of lifter integrated conveyor belt with cams and guides for individual battery cell orientation and sequencing promotes high speed assembly without a need to change component directions. The use of high-speed component delivery high is compatible with allowing more component placement variation, while the edgewise orientation of the components being assembled permits the use of small manufacturing footprints.

Abstract: A method includes the following steps: actuating a robotic arm to perform an action at a start position; moving the robotic arm from the start position toward a first position; determining from a vision process method if a first part from the first position will be ready to be subjected to a first action by the robotic arm once the robotic arm reaches the first position; commencing the execution of the visual processing method for determining the position deviation of the second part from the second position and the readiness of the second part to be subjected to a second action by the robotic arm once the robotic arm reaches the second position; and performing a first action on the first part using the robotic arm with the position deviation of the first part from the first position predetermined by the vision process method.

Abstract: A system and method for stacking battery cells or related assembled components. Generally planar, rectangular (prismatic-shaped) battery cells are moved from an as-received generally vertical stacking orientation to a generally horizontal stacking orientation without the need for robotic pick-and-place equipment. The system includes numerous conveyor belts that work in cooperation with one another to deliver, rotate and stack the cells or their affiliated assemblies. The belts are outfitted with components to facilitate the cell transport and rotation. The coordinated movement between the belts and the components promote the orderly transport and rotation of the cells from a substantially vertical stacking orientation into a substantially horizontal stacking orientation.

Abstract: A battery pack assembly and a method of making the same. The method includes using lifters with a cammed conveyor delivery mechanism to facilitate edgewise stacking of generally planar battery cells. The lifter spacing and cam profile are designed in such a way as to orient individual battery cell tabs and cooling fin assemblies to keep them close together but without applying significant forces to the stackable components. Combining conveyor streams allows components to be processed in parallel and sequenced correctly onto a single conveyor. Use of lifter integrated conveyor belt with cams and guides for individual battery cell orientation and sequencing promotes high speed assembly without a need to change component directions. The use of high-speed component delivery high is compatible with allowing more component placement variation, while the edgewise orientation of the components being assembled permits the use of small manufacturing footprints.