库卡助力利勃海尔公司实现电动汽车电池组组装自动化－国际工业自动化网-专注自动化和数字化的互联网平台

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class="inp_txt" onfocus="if(this.value=='请输入关键字'){this.value='';this.style.color='black'}" onblur="if(this.value==''){this.value='请输入关键字';this.style.color='#C0C0C0'}" autocomplete="off"> </div> <input type="submit" class="submit_btn" value=""> </form> </div> </div><div class="body_c clearfix"> <div class="content_wrap_left"> <h1 id="main_title">库卡助力利勃海尔公司实现电动汽车电池组组装自动化</h1> <p class="sub_title"></p> <div class="artile_attr">&emsp; 2023年11月14日 &emsp; <div class="fr" style="display: none;"> <span class="sooqfont"></span> <em></em> </div> </div> <div id="content"> <P>电动汽车电池的生产过程具有相当大的危险性，因为电池模组的连接会产生极高的电压。Liebherr-Verzahntechnik GmbH(利勃海尔技术有限公司)与 KOSTAL Kontakt Systeme GmbH 和库卡合作，采用 KR CYBERTECH nano 系列机器人，开发了安全高效连接带高电压的电池模组解决方案。</P> <P><STRONG>自动化技术助力电动汽车发展</STRONG></P> <P>电动汽车是未来的主要发展趋势，其不仅有助于减少二氧化碳排放量，并且可降低维修和维护的成本。据估计，目前全球已有超过 2700 万辆插电式混合动力汽车和纯电动汽车。绝大多数国家在2030到2035年将停放燃油汽车的牌照，上述数字预计还会大幅增长。</P> <P>库卡很早就意识到电动汽车的潜力。自 2014 年以来，这家来自德国奥格斯堡的自动化专家便不断地优化其产品组合，以满足汽车工业电子元件制造的特殊要求。位于德国阿尔高地区肯普滕(Kempten)的利勃海尔公司也因此而受益。该公司设计出一款应用程序，在机器人的辅助下，可以为电动汽车制造商及其零部件供应商带来更安全的生产环境和更高的生产效率。电池对于电动汽车来说就像心脏对于人一样重要。</P> <P align=left><STRONG>确保高压电池模块的生产过程更加安全</STRONG></P> <P>高压电池储存着巨大的能量，对车辆的续航里程和充电时间具有决定性意义。高压电池由多个模组构成，这些模组相互电气连接，进而构成一个电池包。连接之后，这些电池系统可输出 400 至 800 伏特的直流电压。然而，由于用于连接模组的铜排裸露在模组表面，会给员工带来极大的安全隐患。</P> <P align=center><IMG onload="javascript:if(this.width>500)this.width=500" border=0 alt="" src="http://www.iianews.com/resupload/00000000000000000011/116002009006/1699952606942_1.png" align=center></P> <P align=center><FONT size=2><STRONG>机器人同时将插拔式模块连接器向下移至电池模块</STRONG></FONT></P> <P>另一种方法则是使用插拔式模块连接器。利勃海尔公司与 KOSTAL Kontakt Systeme GmbH 合作，在机器人的协助下开发了一种用于自动化组装柔性电缆插拔式模块连接器的创新工艺。KOSTAL 的插拔式模块连接器非常灵活且具有绝缘效果，可防止人员意外接触带电部件。即便电缆具有很高的弹性，该系统仍然能够实现自动插入，兼具灵活性和短节拍。</P> <P align=left><STRONG>空心轴机器人和专用软件推动创新</STRONG></P> <P>每个工作单元内有两台 KR CYBERTECH nano ARC HW 负责处理插接过程。一般而言，这些空心轴机器人主要用于气体保护弧焊。然而，其紧凑的设计和大工作范围以及可以将手腕轴作为电缆导管等优点，也使它们成为插接应用的好帮手。此外，利勃海尔团队还选用了软件包 KUKA.RoboTeam。这套软件可以使两台或多台机器人同步协作。软件会实时对照程序和运动，因此即使是复杂的过程(例如连接柔性部件)也不成问题，这是电动汽车领域中的真正创新。</P> <P align=center><IMG onload="javascript:if(this.width>500)this.width=500" border=0 alt="" src="http://www.iianews.com/resupload/00000000000000000011/116002009006/1699952623363_1.png" align=center></P> <P align=center><FONT size=2><STRONG>两台 KR CYBERTECH nano ARC HW 在一个工作单元中插接电子连接</STRONG></FONT></P> <P align=left><STRONG>专业技术人员短缺促使自动化向前发展</STRONG></P> <P>为了满足新能源汽车生产中对节拍、数量、质量和生产成本等多方面更高的要求，电池生产过程中的大部分流程如今已经实现自动化。此外，专业技术人员短缺也推动了自动化的强劲趋势。愿意承担这种单调、体力负担重、同时又要求严苛的任务的专业技术人员越来越少。</P> <P align=center><IMG onload="javascript:if(this.width>500)this.width=500" border=0 alt="" src="http://www.iianews.com/resupload/00000000000000000011/116002009006/1699952636509_1.png" align=center></P> <P align=center><FONT size=2><STRONG>KR CYBERTECH nano ARC HW 的设计修长，因此可以将两台机器人安装在一个紧凑的工作单元中</STRONG></FONT></P> <P>来自德国吕登沙伊德(Lüdenscheid)的 KOSTAL Kontakt Systeme GmbH 公司自 1938 年以来致力于生产和销售汽车工业用的连接器。这家公司意识到这块市场仍然空白，因此开发了一款同时适合手动和自动化的插接头。KOSTAL 开发团队负责人 Martin Wolter 表示：“安全性在这里非常重要。这里所处理的是高压触点，因此必须防止意外接触。类似于插座，这里的触点也受到保护，防止手指意外触碰。然而，不同之处在于车辆中的插头连接会受到振动以及高温和低温的影响。”</P> <P align=left><STRONG>电动汽车电池组组装的里程碑</STRONG></P> <P>随后 KOSTAL 开始寻找自动化专家，旨在使新品能够适合量产。KOSTAL 在肯普滕的利勃海尔公司找到了他们需要的技术。自 1969 年以来，这家来自阿尔高地区的公司一直为众多汽车制造商和零部件供应商以及设备制造、航空航天和建筑机械领域的客户提供创新解决方案。</P> <P align=center><IMG onload="javascript:if(this.width>500)this.width=500" border=0 alt="" src="http://www.iianews.com/resupload/00000000000000000011/116002009006/1699952656581_1.png" align=center></P> <P align=center><FONT size=2><STRONG>自动化系统产品经理Viktor Bayrhof 站在创新的工作单元前，这个工作单元仅在一年半后就在电池展上亮相</STRONG></FONT></P> <P>自动化系统产品经理 Viktor Bayrhof 表示：“这是一个双赢局面。作为最近才加入电池组装领域的新参与者，我们找到了独特的卖点。KOSTAL 公司也找到了能够实现产品自动化的伙伴。”这三家公司合作了一年半后，新的机器人单元就已经在德国斯图加特的电池展上展出了。</P> <P><STRONG>安装：机器人插接柔性电缆</STRONG></P> <P>它们在展会上备受瞩目，因为带柔性电缆的插拔式模块连接器较带母线的螺钉连接具有更多优势，它们只需将连接器和配合件相互连接，因此更容易组装。此外，它们可以吸收车辆运行期间的振动，因而减少因磨损而导致失去接触的情况。在日后更换电池模块、二次使用或回收电池组模块时，这样的设计也更具有优势。唯一的问题就是，由于电缆是柔性的，因此即使在施加很小的力或力矩下也会变形，使普通的自动化设备难以处理。</P> <P align=center><IMG onload="javascript:if(this.width>500)this.width=500" border=0 alt="" src="http://www.iianews.com/resupload/00000000000000000011/116002009006/1699952671339_1.png" align=center></P> <P align=center><FONT size=2><STRONG>稳固连接 – 这是推广电动汽车过程中极其重要的一步</STRONG></FONT></P> <P align=left><STRONG>加工柔性部件需要优异的解决方案</STRONG></P> <P>用机器处理柔性部件仍然是现今组装任务中的一个巨大挑战。例如，机器人很难抓住会向任何方向扭曲的弹性电缆。利勃海尔公司以 KR CYBERTECH nano ARC HW 为基础，开发出一款特殊夹爪，可以从泡壳中取出电缆。由于泡壳中的电缆事先没有精确地放在一定位置上，因此会采用 2D 摄像机，以便准确找出高弹性柔性电缆上的抓取位置，并将电缆末端的模块连接器精确定位在连接器配合件的上方。</P> <P align=center><IMG onload="javascript:if(this.width>500)this.width=500" border=0 alt="" src="http://www.iianews.com/resupload/00000000000000000011/116002009006/1699952681640_1.png" align=center></P> <P align=center><FONT size=2><STRONG>在 2D 摄像机的辅助下，机器人可以精确地抓取并插接高压电池的柔性部件</STRONG></FONT></P> <P align=left><STRONG>弹簧组提供恰到好处的力量</STRONG></P> <P>由于连接器必须小心处理，因此将插接过程解耦以确保顺利运行。一个弹簧组负责控制传输到连接器和连接器位置保证(CPA)的力。然后，气缸将连接器压入连接器配合件中。这个弹簧组件会受到加压，直到达到 70 Nm的力矩并触发终端位置传感器。同时，弹簧承载的锁定销将 CPA 向下推。这样会使 CPA 锁定，连接器牢固插入，夹爪便可以再次向上移动。</P> <P>与其他自动化专业供货商相比，利勃海尔公司刻意避免将试错过程作为柔性电缆的插接过程的解决方案，因为每一个抓取动作都必须一次到位。他们这样做的原因是，该技术应适合量产，并且必须能够满足严格要求的周期时间。结果证明，这非常有效。系统的节拍比规定的 17 秒更短，创造了 11 秒的佳绩。</P> <P align=left><STRONG>合适的机器人与软件组合带来优异性能</STRONG></P> <P>自动化制程中采用了 KR CYBERTECH nano ARC HW。这款灵活、经济高效的工业机器人专门用于处理小型工件，而且还可以到达难以接近的插接位置。此外，其也具有不受控静电充电或放电 (ESD) 保护，非常适合处理敏感电子元件。值得一提的还有，这款设计紧凑的机器人可以充分利用狭小的空间。</P> <P align=center><IMG onload="javascript:if(this.width>500)this.width=500" border=0 alt="" src="http://www.iianews.com/resupload/00000000000000000011/116002009006/1699952696706_1.png" width=500 align=center></P> <P align=center><FONT size=2><STRONG>电池生产的每个步骤都可以使用 KUKA smartPAD 手持操作设备进行跟踪和控制</STRONG></FONT></P> <P>利勃海尔公司利用软件 KUKA.RoboTeam 使两个夹爪能够像人类手臂一样，在主控-从站-运作模式之下良好地配合。这样一来，机器人可以处理不同的电缆长度和插接位置，并补偿位置公差。集成图像识别系统有助于确定插槽的真实位置。此外，该解决方案不仅可用于电接触，还可用于电池生产中的其他弹性组件，例如，电池管理系统 (BMS) 和电池管理控制器 (CMC) 之间数据线的自动插接过程。</P> <P><STRONG>高质量标准：准备好迎接电动汽车</STRONG></P> <P>库卡的电子行业全球业务发展经理 Martin Klaus 表示，汽车行业中的许多公司只有在自动化的帮助下才能在未来保持竞争力。Klaus 强调说：“由于电动汽车的发展趋势以及车辆技术的日益进步，汽车中复杂电子元件的数量和种类正在显著增加，”Klaus 继续说，“这些组件，包括逆变器、电机、显示器、摄像机和控制单元，只能以高度自动化的方式制造，才能达到所需的质量和数量。</P> <P align=center><IMG onload="javascript:if(this.width>500)this.width=500" border=0 alt="" src="http://www.iianews.com/resupload/00000000000000000011/116002009006/1699952709242_1.png" width=500 align=center></P> <P align=center><FONT size=2><STRONG>通过硬件和软件的交互，各个组件都非常容易控制</STRONG></FONT></P> <P align=left><STRONG>电池组组装领域的新合作伙伴关系前景无限</STRONG></P> <P>机器人专家库卡已为此做好准备，其产品组合中拥有 ESD 保护机器人以及经过洁净室和干燥室认证的机器人。利勃海尔公司的 Viktor Bayrhof 也认为：“高压电池系统是电动汽车中最昂贵的组件。为了以更经济的方式大量生产这些电池，自动化技术发挥着关键性的作用。”这三家公司参与开发的解决方案能够确保公司的竞争力，因为他们可以持续改进生产过程，包括对柔性部件处理。</P><p align=right>（库卡在线）</p></div> <div 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