Battery & Energy Industry

Alliance Automation is developing the next generation of scalable automation for manufacturers who are transforming the electric battery production process. We have automation for cell-to-module packaging, modules, trays, and assembly processes that expand our capabilities beyond machine building and robotic integration. Our high-speed cell picking, welding, fastening, riveting, and material handling stations allow us to combine the best human and automated assembly methods to manufacture battery packs.

Battery Assembly and Inspection

Key Functions

Processes 7 CMA configurations and split CMA
System will assemble a top and bottom cell holder and collector plates, cells, two sleeves
Weekly volume of 7,500 pieces
Machine cycle of 30 seconds part to part
System capacity set for five days per week, two shifts, 7.5 hours per shift
Will hold parts to build 60-90 units
Equipment requires one material loading operator
Floor space will be 48’ long X 18” wide

Components

(5) Six station rotary index table – rotary nest hold 27 parts or 60 parts
(10) Pick and Place Unit
(1) linear actuator
(1) pneumatic vertical cylinder
(1) 90° rotate cylinder
(2) pneumatic grippers.
(8) Inspection Sensors
(3) Reject Tote with High Level Sensor
(1) Cell dispense magazine – holds 150-200 cells
(2) Hioki Battery Tester
(2) Test probe
(9) Cell waterfall holders
(4) Cell polarity test using probes and pneumatic cylinders
(1) Fanuc M2iA/3A six axis delta robot with vacuum suction cup pick
(1) Fanuc M20iD/25 six axis robot with End of Arm Tool – (2) Magswitch, (2) Magswitch shoes, (2) Insulator Lid Grippers
(1) Scrap Bin for Empty Cell Box and Insulator Tops
(3) Vibratory bowl feeder – with vibratory inline, part escapement and sound enclosure
(1) Inspection Camera.
(3) Fanuc SR-12iA SCARA Robot w/R30iB Compact Plus Controller
(2) Glue Dispense Controller
(6) Glue Dispense Valves
(4) Glue Tip Linear Actuators
(2) 5 Gallon SS Pail
(1) Glue Purge Station
(2) Air Accumulation Tank
(1) Twelve station rotary index table – for plate assembly.
(1) Cognex In-Sight D905 Camera with Vidi Starter Kit 201
(1) UV ring/area light
(1) Keyence Laser Unit
(2) Laser enclosure
(2) Pneumatic actuated doors
(2) Safety interlocked door switches
(1) Air Knife
(2) Fume Extraction – Fumex Model FA1
(2) Fuse/Bond machines
(4) Pneumatic actuated rotating clamp cylinders
(4) Clamp tooling
(1) Reject Belt Conveyor
(2) Part Present Sensors
(1) Fanuc M710iC/20M Robot with IR Vision
(2) Dunnage Stations
(1) Layer Divider Station
(1) Dual End of Arm Tool – pneumatic grippers to pick CMA, suction cup unit to pick layer dividers.
(1) Guarding – free standing wire mesh guarding with (1) safety interlocked access door.
(6) Two Strand Conveyor – 5 meter sections
(2) End Transfer Units
(8) Motor with Variable Frequency Drive
(35) Pallets, 240mm x 3200mm
(20) Lift and Locate Units
(35) Pallet Stops – Dampened
(1) Allen Bradley Compact Logix Safety PLC
(1) High Volt Electrical Disconnect Enclosure
(1) Low Volt Electrical Enclosure
(3) Operator Interface Units (supplied by Briggs & Stratton)
(3) Ignition Software
(3) RFID Badge Reader
(19) Remote Input / Output Modules
(5) Safety Interlocked Access Doors
(2) Battery Test Probe
(2) Battery Test Probe Cylinder

The Project

Due to the increased demand of batteries, companies are looking to Alliance Automation to develop innovative designs to overcome assembly challenges. Mistake proofing the assembly process is paramount to the assembly cells, quality is king in battery production and testing. Assembly cells must increase speed of production, reduce scrape, improve throughput efficiency, and allow for minimum operator interaction. To reduce floor space, each cell will assemble multiple configuration types to be ran on the same equipment with a fast change over. Scanning and collecting test data from production is readily available.

Battery Assembly Line

Key Functions

System consists of two separate assembly lines with glide line over under palletized conveyor.
Builds one type of battery pack model.
Assembly status of each pallet tracked using RFID tags.
Mistake proofing sensors used at operator locations where part presence or absence must be verified.
Operator interface units will have screens that can switch between English and Spanish.
Equipment designed to allow for future battery packs to be built minor redesign.
Production capacity is one unit every 14.5 seconds, faster time is available.
Capacity is subject to operator load and unload efficiency. This design requires eight operators.
Line will dispense cells to be assembled with rubber wedges and load frames.
Isolation pads, load cell frame, straps, PCB and foam pads will be manually loaded.
System will weld straps in 1.5 seconds and apply screws in 2.5 seconds.
Thermal adhesive will be applied by the automation.
Negative & Positive straps and soldering automatically.
EOL will be test three packs at one time with 25 seconds test time.
Laser Etching
Side and bottom labels applied
Manual unload

Components

(1) Cell Hopper
(1) Fanuc M20iD/25 with End of Arm Tool
(2) Magswitch AR70 Magentic Gripper
(2) Magswitch AR70 Pole Shoe
(1) 9” x 9” Fixture Plate
(1) Fixed Barcode Reader
(1) 6’-6” Powered Infeed Conveyor
(1) 6’-6” Gravity Conveyor
(1) Guarding
(1) Cell Dispense Unit – rotary tooling on stepper motor
(1) Hioki BT3561A Battery tester with switch mainframe & multiplexer module
(1) Pneumatic Part Stop Cylinder
(1) Pneumatic Reject Chute Cylinder
(1) Pneumatic Test Probe Cylinder
(1) Reject Tote
(8) Part Detect Sensor – cells at end of chute, cell at stop, and reject tote full.
(2) Assembly Fixture
(5) Keyence Vision Sensors
(7) Operator Station Box with (1) “Process Complete” Push Button (PB), (1) “Reject” PB,
(1) 3-Color Indicator
(1) Emergency Stop
(2) 36” Long Belt Conveyor for Loading Cell Frames
(1) Pneumatic pick and place unit with pneumatic gripper fingers.
(1) Cell Frame Magazine
(2) Cell Frame Escapement Cylinders
(2) Cell and Wedge Press Fixture
(2) Pneumatic Overhead Press Cylinders
(2) IAI Linear Press Actuators
(3) Keyence Vision Sensor
(3) Mounting for HF2S/460 High frequency weld inverters and TL088B-EZ Weld Head
(4) Pneumatic cylinder for X and Y weld head movement
(1) Servo controlled rack & pinion for horizontal movement of weld head from cell to cell.
(1) Hioki RM3545-02 Resistance Meter with multiplexer module.
(6) Test Probes
(1) Graco Dispensit 1052 – Meter and Dispense System
(1) Graco Dispensit Cartridge 3A1452EN – 20 oz. cartridge feed
(4) Visumatic integrated screw feed System – holds minimum of 1 hour worth of screws
(3) Desoutter ERSF-M20 DC Electric Drive Spindle with CVIR Controller
(1) Screw diverter
(6) Pneumatic cylinder to adjust PCBA location
(4) Screw load chutes with door flap
(4) Pneumatic cylinder for door flap
(2) Handheld Scanner
(1) Apollo Seiko Terra Controller with Solder Iron Unit – 200 Watt
(1) Apollo Seiko ZSB Solder Feeding Unit
(1) Apollo Seiko SRC-500DC Rotary Tip Cleaner
(1) Purex Fume Extractor
(1) Keyence Vision Camera
(1) Pneumatic Rotary Cylinder
(2) Pneumatic X, Y Cylinder
(1) Protective Cover Pneumatic Cylinder
(4) Battery pack connector
(1) Keyence ML-Z9600 3-Axis C02 Laser Marker Controller
(1) Keyence ML-Z9610 3-Axis C02 Laser Marker Head
(1) Marking Station Shroud
(2) Pneumatic safety doors
(2) Safety Switches
(1) Fume Extractor
(1) Pneumatic Pick and Place Unit
(1) Pneumatic Gripper Cylinder with Gripper Fingers
(1) 36” Reject Belt Conveyor with Cover
(1) Intermec Label Printer
(1) Tolerance Ring sensor
(2) CTM, EPI or Label-Air Label Applicator
(1) Pneumatic Part Gripper and Lift
(1) CTM, EPI or Label-Air Label Applicator

The Project

Future proofing your battery manufacturing process is a key element of any automation project. This project required Alliance Automation to assemble and test battery packs on two separate lines. The customer was not certain of the future of the specific battery, so Alliance developed a design that would allow the customer to alter the type of battery packs that would run on the line and could also reduce the number of operators need to operate it in the future. This system also offers English and Spanish text, ensuring that no matter who operates it they can read the screens.

Battery and Energy Automation Opportunity Areas:

  • Assembly
  • Material handling
  • Joining
  • Cell test and load
  • Measurement
  • Conveyor
  • Operator-assisted stations
  • Inspection and testing

Companies need a partner they can trust to install robotics, vision, laser inspection, sensors, and part testing into their production lines. Whether it is a fully automated line or specific tasks, automated equipment is ideal for completing repetitive tasks like moving parts across stations, applying sealants, and joining materials.

Is Battery and Energy Automation Right for your Business?

  • Does your current process include several steps that require precision welds, accurate placement, and is highly repetitive?
  • Could you increase your production rates? Are you struggling with throughput capabilities?
  • Have high-speed areas made proper testing, quality control, and safety a challenge?
  • Are labor challenges at the top of your company's major concerns?
  • Can you count on your current automation partner to provide an all-inclusive turnkey solution, or do they have to outsource?
  • Are you required to provide proper traceability and data to your customers?

If your answer yes to any of these questions, call us!

Why you should Join the Alliance

When you partner with Alliance Automation you're getting more than just a robotic solution.

Alliance Automation is here to design, build and install a custom solution to fit your exact needs. Our products will solve your business challenges. How? We follow the Alliance Proven Process. Alliance Automation doesn’t just sell you a product; we get to know your business and find solutions to help you reach your goals.

 What we offer:

  • Project Review
  • Risk Analysis and Risk Assessments
  • Budgetary and complete project proposals
  • CAD Designers
  • Fabrication
  • Toolmakers
  • Machinists
  • Mechanical Engineers
  • Electrical Engineers
  • Controls Engineers
  • Project Managers
  • Full Implementation teams