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fit the equipment and strict budget
parameters, as well as a lead-in time of
just seven months. We also needed to
find a way of electrically testing each
cell, rotating cells on demand and placing
the cells into each module with high
degrees of accuracy and at speed.”
Put to the test
The pilot line required groups of 30 cells
to be tested simultaneously for current
and voltage before each cell was picked
and placed in the battery modules. WMG
had identified a standard battery testing
unit as being fit for purpose, but unit
costs and space constraints meant that it
was not possible to accommodate 30
individual battery testers. To solve this
problem Horizon and WMG developed a
bespoke multiplexer interface which
allowed a single battery tester to be
used. This not only delivered savings on
space and capital cost, but enabled data
collation regarding test status.
The area available for battery assembly
system is rectangular and measures
approximately 1.2 metres by 2.0 metres.
The system spans a through flow
conveyor. Following testing, the battery
cells need aligning accurately and
sometimes inverting before being
inserted into the module located on the
conveyor. The number of battery cells
required for a module varies and is
configurable via a recipe. 100 individual
cells per module is typical, with a total
weight of approximately 9kg once
assembled.
Again, space was at a premium. There
was not sufficient room to employ a
standard robotics solution, which would
require a circular movement around the
module in order to place all the
components. Another novel solution was
required.
Horizon considered a number of options
to arrive at a bespoke design, but Festo
automation won for several reasons. “We
were confident in the quality of the
technology, having worked with Festo on
previous occasions,” says Daniel. “More
importantly for this project, Festo were
capable of delivering a total Cartesian
robot solution; so we didn’t need to co-
ordinate multiple suppliers or worry
about product compatibility. They
delivered a custom, cost-competitive
system within eight weeks of the order
being placed and also provided technical
support throughout the design,
installation and commissioning process.”
Festo automated solution
At the heart of the AMPLiFII battery pick
and place system is the Festo EXCH 60
H-Handler, a highly dynamic 2D planar
surface gantry, controlled by a Festo CPX
valve terminal.
The EXCH is aimed at high-speed
assembly operations where small, light
mass-produced items need to be
positioned quickly and flexibly. The
gantry has a rectangular working area,
which makes it more economical than
SCARA and delta kinematic robots: both
in terms of mass – around 150kg – and
space requirements. The EXCH has a
standard XY axis, but its single belt
enables precise positioning at high
speeds within a compact envelope. It
also features a connector so that Z axis
equipment such as a gripper can be
integrated into the handling system with
ease.
Powered by two fixed motors, the EXCH
H-Handler delivers an optimum dynamic
response when compared with other
Cartesian gantry systems. By eliminating
the need to use separate gantries for
each axis, the EXCH delivers very precise
alignment. It operates at speeds of up to
5m/s and acceleration rates of up to
50m/s
2
, and is capable of 100 picks per
minute with a repetition accuracy of +/-
0.1mm.
The CPX terminal used to control the cell
picking activity is Festo’s flagship
automation platform, allowing state of
the art electronics and pneumatics to sit
on a single, stand alone base. With
modules available for PLC control,
multiple fieldbus standards, motion
control, inputs and outputs, the CPX
reduces the number of components on
the machine whilst giving the controls
engineer all the flexibility they could
need.
This combination of control, speed and
precision was critical to the success of
the battery pack assembly line in
demonstrating commercial viability.
EXCH 60 H-Handler:
a highly dynamic 2D planar
surface gantry, controlled by a Festo CPX valve
terminal.
Automation solutions provider
Horizon Instruments designed
and integrated the Festo Handler and conveyor system