Description:FIELD OF INVENTION

[001] The present invention relates to a device for performing machining operations, and particularly to a movable pallet device for adaptive laser bonding process with integrated loading and unloading systems.

BACKGROUND OF THE INVENTION

[002] In precision manufacturing and assembly processes, accurate positioning of components is critical to achieving high-quality outcomes. Workpiece components or parts in manufacturing or assembly lines are handled with precise accuracy while carrying out desired operations by lathe machines or jigs. Lathe machines are widely used for their versatility and precision, making them suitable for shaping, cutting and finishing different parts and components. Lathe machines have limitations in producing industrial components, and therefore jigs are used to produce identical industrial articles in bulk. Jigs rigidly hold a workpiece and guide different tools to precisely locate and perform various machining operations such as drilling, milling, planning, tapping, grinding, etc., on the workpiece. Jigs include different types of fixture tools to hold, support and position workpiece components during assembly, machining, or welding operations.

[003] Indexing generally refers to the process of rotating a workpiece to a specific position or angle to allow for precise machining operations by machine tools. This can be achieved either by rotating machine tools to a specific position or angle to access desired areas of the workpiece, or by using indexing base which firmly hold and rotate the workpiece to align desired areas with the machine tools so that desired machining operations can be performed. Therefore, jigs and fixtures are essential tools for holding, supporting, and aligning workpieces and performing machining operations thereon in industrial environments.

[004] Reference may be made to the publication Jig and Fixture Design Manual by Erik Karl Henriksen, which provides comprehensive coverage of the fundamental principles of jig and fixture design, including locating, clamping, and the mechanics of cutting tool operations. Also, the publication Design of Jigs, Fixtures and Press Tools by Venkataraman describes various aspects of jig and fixture design, including illustrations and detailed explanations of different types of fixtures. Further, the publication Mechanical Design and Packaging of Battery Packs for Electric Vehicles by Arora et al discusses the mechanical design elements and packaging solutions for battery packs, focusing on safety and reliability.

[005] Chinese patent document CN105081406B discloses a mechanism and boring method for indexing drilling radial holes. The document solves the problem of repetitive designing and assembly of fixtures for drilling radial holes of different circumferences and angles for varying product requirements by providing a universal interchangeable structure. However, the document is limited to a steady rectangular base plate with uniform-sized T-shaped grooves provided for indexing drilling radial holes on products and different positioning clamping mechanisms.

[006] Further, the patent publication document WO2020103551A1 discloses a formation capacity-grading equipment with hot-and cold-press clamps for a soft-package lithium battery. The document solves the problem of separate hot and cold pressing formation processes for capacity grading of lithium batteries and integrates production lines used for producing lithium batteries. The disclosure is limited to the superimposing of different capacity grading devices to form a layered structure with a maintenance unit mounted laterally thereto which solves the problem of separate pressing formation processes.

[007] The presently known mechanisms provide platforms with limited adaptability in industrial environments while performing machining operations on workpieces and products. So, there is a need for an adaptable device that allows performing machining operations on workpieces or products such as battery cells module by manually moving the device in different directions which not only reduces operators’ risk but also improves accuracy during indexing fixtures of workpieces or products.

OBJECTIVES OF THE INVENTION

[008] The primary objective of the present invention is to provide a device for adaptive laser bonding process with integrated loading and unloading systems.

[009] Another objective of the present invention is to provide a device having an adaptive mechanism which enables operators to manually move the work piece or components need to be bonded in two different directions.
[0010] Yet another objective of the present invention is to provide a device with indexing mechanism for performing laser bonding operations, thereby giving flexibility in operating the device and ensuring safety of both the machine and the operator.

[0011] Yet another objective of the present invention is to provide a device for adaptive laser bonding process with integrated loading and unloading systems which minimizes the risk of accidents while ensuring that the laser’s operational parameters are not disrupted.

[0012] Yet another objective of the present invention is to provide a device which is adaptable to different machine dimensions, particularly existing laser bonding machines’ bed sizes, enabling integration of the embodiments of the present invention with the existing machines which removes the need for costly upgrades or reconfiguration of the machines.

[0013] Yet another objective of the present invention is to provide a device with an adaptive mechanism to easily move the battery or cell module into the machine through input and output stations having a gap and help in easy movement of cell modules with different heights.

[0014] Other objectives and advantages of the present invention will become apparent from the following description taken in connection with the accompanying drawings, wherein, by way of illustration and example, the aspects of the present invention are disclosed.

SUMMARY OF THE INVENTION

[0015] The present invention discloses a movable pallet device for an adaptive laser bonding process with integrated loading and unloading systems. The pallet device is provided for indexing fixtures of workpiece components or parts to be laser bonded. This fixture is particularly valuable in applications such as laser bonding, machining, and assembly, where even slight misalignments can lead to defects, inefficiencies, or compromised performance.

[0016] The pallet device comprises a base pallet, a battery module holding pallet, guide rails mounted on the base pallet, guide blocks arranged on the holding pallet, bearing holders installed on the base pallet, and dowel bushes installed on the holding pallet. The base pallet is configured to move in the X-axis direction using bearing holders arranged to slide on guides of an outer structure assembly and the holding pallet is configured to slide in the orthogonal Y-axis direction on the guide rails of the base pallet. The manual X-Y indexing fixture serves as an essential tool that allows operators to position workpieces including battery modules with precision along two axes. The outer structure assembly is made of metal square tubes welded together to add truss support and guides for the bearing holders of the pallet device to allow it freely slide without any deflection. The problem of transferring the pallet device from one station to another through the gaps is solved by the pallet and outer structure assembly design, wherein at the time of transfer pallet self-weight and due to a series of bearing assembly arrangements prevents the pallet device from falling and it easily moves from one station to another. Also, chamfers are provided at the entry of all stations and outer structures guide rails so that the pallet device will be easily guided to slide or move between different structures without any interruption.

[0017] The present invention provides a combination of durability, flexibility, and ease of use which make it suitable for applications ranging from laser bonding to machining and assembly. By allowing for accurate, manual adjustments, the fixture enhances workflow efficiency and improves the quality of outcomes. As manufacturing processes continue to demand greater precision and adaptability, the manual X-Y indexing fixture remains a relevant and essential tool in the industry.

BRIEF DESCRIPTION OF DRAWINGS

[0018] A complete understanding of the present invention may be obtained by reference to the accompanying drawings, when taken in conjunction with the detailed description thereof and in which:

[0019] Figure 1 illustrates a front view of a pallet device.

[0020] Figure 2 illustrates a side view of the pallet device arranged on an outer structure assembly.

[0021] Figure 3 illustrates front and side views of a bearing holder of the pallet device.

[0022] Figure 4 illustrates a top view of a base of the pallet device.

[0023] Figure 5 illustrates an isometric view of the pallet device.

[0024] Figure 6 illustrates a top schematic view showing the working area of the pallet device.

[0025] Figure 7 illustrates a front view of the pallet device configuration with input and output stations.

[0026] Figure 8 illustrates a gap between the outer structure assembly carrying the pallet device and the input/ output station.

[0027] Figure 9A illustrates an outer structure assembly for carrying the pallet device.

[0028] Figure 9B illustrates a corner portion of the outer structure assembly showing a guide chamfer for entry of the bearing assembly of the pallet device.

[0029] Figure 10 illustrates a perspective view of the outer structure assembly with a poke-yoke block showing the movement of the pallet thereon.

DETAILED DESCRIPTION OF THE INVENTION

[0030] The following description describes various features and functions of the disclosed invention with reference to the accompanying figures. In the figures, similar symbols identify similar components, unless context dictates otherwise. The illustrative aspects described herein are not meant to be limiting. It may be readily understood that certain aspects of the disclosed mobility and walking assistance device can be arranged and combined in a wide variety of different configurations, all of which are contemplated herein.

[0031] Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope of the invention. In addition, descriptions of well-known functions and constructions are omitted for clarity and conciseness.

[0032] Features that are described and/or illustrated with respect to one embodiment may be used in the same way or in a similar way in one or more other embodiments and/or in combination with or instead of the features of the other embodiments.

[0033] The terms and words used in the following description and claims are not limited to the bibliographical meanings but are merely used to enable a clear and consistent understanding of the invention. Accordingly, it should be apparent to those skilled in the art that the following description of exemplary embodiments of the present invention are provided for illustration purpose only and not for the purpose of limiting the invention.

[0034] It is to be understood that the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.

[0035] It should be emphasized that the term “comprises/comprising” when used in this specification is taken to specify the presence of stated features, integers, steps or components but does not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof. The equations used in the specification are only for computation purposes.

[0036] While this invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims.

[0037] A pallet device 10 is disclosed, wherein the device 10 is loaded on an outer structure assembly 11 and configured to move or slide from an input station 13 to the outer structure assembly 11 and further to an output station 14, the outer structure assembly 11 and input/ output station are separated by a gap 15 having a discontinuity between therein. The gap 15 may have a width between 5 mm to 20 mm which may vary as per the requirements. In a preferred embodiment, the gap of 15 mm is provided between the outer structure assembly carrying the pallet device 10 and the input station 13 or the output station 14. The pallet device 10 is provided for indexing fixture of a workpiece component, preferably a battery module, in a two-dimensional plane, i.e., X and Y axes. The pallet device 10 comprises at least two platforms including a lower base pallet 1 configured to move on the outer structure assembly 11 and an upper pallet 2 configured to move on the lower base pallet 1, wherein each platform is configured to move in a different X or Y axis direction.

[0038] Fig. 1 illustrates a front view of a movable pallet device 10 for indexing workpiece components or parts. In some embodiments, the pallet device 10 comprises a base pallet 1, a cell module holding pallet 2, at least two guide rails 3 mounted on the base pallet 1, a plurality of guide blocks 4 arranged on the holding pallet 2, a plurality of bearing holders 5 installed on the base pallet 1, and a plurality of dowel bushes 6 and handles 6A mounted on the holding pallet 2 and base pallet 1 respectively. The base pallet 1 is configured to move in the X-axis direction using the bearing holders 5 which are arranged on at least two guides 9 of the outer structure assembly 11 as illustrated in Fig. 2.

[0039] In some exemplary embodiments, the base pallet 1 and the holding pallet 2 are made of a flame retardant material, for example, but not limited to FR4 grade material. It should be noted that the battery modules may have the risk of electricity leak and therefore pallets 1 and 2 should be non-conductive and may not be burned or melted at increased temperatures. The FR4 material is specifically used in those areas where the products are in contact with the electricity and should withstand the load because of the glossy particles that are in-plunged with composite particles.

[0040] Fig. 2 illustrates a side view of the pallet device 10 arranged on the outer structure assembly 11, wherein the bearing holders 5 of the base pallet 1 are configured to slide on the guides 9 of the outer structure assembly 11 in the required direction only and don’t move in any other direction. For example, as illustrated in Fig. 5, the base pallet 1 is configured to move in x-axis direction whereas the holding pallet 2 is configured to move in an orthogonal y-axis direction.

[0041] Fig. 3 illustrates the bearing holder 5 assembly which helps to move the pallet device 10 in one direction freely, e.g., x-axis. In an exemplary embodiment, the base pallet 1 contains at least 12 bearing holders. In some embodiments, the bearing holder 5 assembly may be assembled using Allen screws with thread in one block and the alignment is performed using the transition fit.

[0042] Fig. 4 illustrates a planar view of the base pallet 1 and Fig. 5 illustrates a perspective view of the pallet device 10. The holding pallet 2 is configured to move in Y-axis direction orthogonal to the base pallet 1 movement of X-axis direction. In some embodiments, the holding pallet 2 comprises four guide blocks 4 allowed to move on the guide rails 3 attached to the base pallet 1 with the step cutout for the position alignment which is marked in Fig 4. In some embodiments, the guide rails 3 and the guide blocks 4 are attached using Allen screws, wherein the balls of the guide blocks 4 provide smooth movement on the surface of the guide rails 3.

[0043] The handles 6A are attached to the base pallet 1 which help in moving the pallet device 10 manually on the guides 9 of the outer structure assembly 11. In some embodiments, the handles 6A are mounted on the base pallet 1 using countersunk screws. The dowel bushes 6 are attached to the holding pallet 2 and are used for positioning the holding pallet 2 in Y-axis direction. In some embodiments, the dowel bush 6 is made of hardened material, e.g., EN34 hardened steel, because of its high usability at the time of production. The dowel bush 6 may be used in high wear and tear areas and that is to be fixed using Allen screws. In some other embodiments, alternative wire inserts, e.g., proprietary helicoils threads, may be used in fire retardant materials, e.g., FR4, where composite material tapping is not suitable.

[0044] Fig. 6 illustrates the working area of the pallet device, wherein the pallet device 10 is arranged on the outer structure assembly 11 limited by an arrangement of a pallet locking area 12 and bearing assemblies 8. The bearing assembly 8 is shown in Fig. 9A. In an exemplary embodiment, the pallet locking area 12 is made of aluminium extrusions.

[0045] Fig. 7 illustrates a configuration of the pallet device 10 with input 13 and output 14 stations. The pallet device 10 may be moved from the input station 13 to a machine in an area containing the outer structure assembly 11 for performing desired bonding operations where different tools operate on the workpiece component, i.e., battery cell module, placed on the working area of the pallet device 10. After completion of bonding operations, the pallet device 10 moved out from the machine area to the output station 14. The machine and input/ output stations are separated by a preferred gap width of 15mm as shown in Fig. 8. The gap 15 may have a width between 5 mm to 20 mm which may vary as per the requirements. A poke-yoke block 7 is provided to control the reversing of the pallet device as shown in Figs. 9A & 10. The movement of the pallet device 10 between the machine and the stations 13, 14 is smooth due to chamfers 17 provided at corners of the outer structure assembly 11 and stations 13, 14 as shown in Fig. 9B.

[0046] In some embodiments, the working area may be smaller than the workpiece including but not limited to a battery module, therefore indexing for Y-axis may be used to achieve the output without any major changes on the machine, and the fixed plate is removed because the cell is not moved without any damages due to more self-weight.

[0047] In the inner assembly like the outer structure assembly 11, the bearing assembly 8 may be assembled at the centre to withstand the load having adjustments, e.g., +12.5 mm to -12.5 mm from the centre.

[0048] Figs. 9A and 9B illustrate the outer structure assembly 11, which is made of square tubes welded together to add truss support and guides 9 for the pallet rollers, i.e., bearing holders 5, to move the pallet device 10 freely thereon without any deflection or interference. The problem of transferring the pallet device 10 from one station to another station through the gap 15 is solved by the pallet and outer structure assembly design, wherein at the time of transfer pallet self-weight and due to a series of bearing assembly arrangement, the pallet device 10 is prevented from falling and it easily moves from one station to another. Also, chamfers 17 are provided at the entry of all stations’ guides, e.g., guides 9 of the outer structure assembly 11, so it will easily guide the bearing to the path without any interruption. In some embodiments, levelling mounts may be provided for the structure’s stability and may be added to the structure by a threaded rod.

[0049] In an embodiment, the present invention provides an indexing pallet device 10 for adaptive laser bonding process with integrated loading and unloading systems, comprising: an outer structure assembly 11 comprises a poke-yoke block 7, pallet rollers 8, and guides 9, wherein the device 10 is configured to slide from an input station 13 to the assembly 11 and further to an output station 14 on the guides 9 and pallet rollers 8 of the assembly 11; a base pallet 1 comprises at least two guide rails 3 attached on upper surface and a plurality of bearing holders 5 attached on lower surface, wherein the base pallet 1 is configured to slide on the guides 9 and pallet rollers 8 of the outer structure assembly 11 in a single direction between the input 13 and output 14 stations having a gap 15 between therein; and a holding pallet 2 comprises a plurality of guide blocks 4 on lower surface and a working area on upper surface, wherein the holding pallet 2 is configured to slide on the guide rails 3 of the base pallet 1 in a direction orthogonal to the base pallet 1. The poke-yoke block 7 is provided to control the reversing of the device 10. The device 10 is configured to move smoothly between the assembly 11 and the stations 13, 14 due to chamfers 17 provided at corners of the outer structure assembly 11 and stations 13, 14.

[0050] In another embodiment, the present invention provides a device 10, wherein the direction of the base pallet 1 is on x-axis and the direction of the holding pallet 2 is on y-axis.

[0051] In yet another embodiment, the present invention provides a device 10, wherein the device 10 comprises a plurality of dowel bushes 6 and handles 6A, the dowel bushes 6 are attached to the holding pallet 2 to position the holding pallet 2 in the y-axis direction and the handles 6A are attached to the base pallet 1 to slide the base pallet 1 in the x-axis direction.

[0052] In yet another embodiment, the present invention provides a device 10, wherein the plurality of bearing holders 5 in the base pallet 1 enable the device 10 to slide through gaps 15 between the stations 14, 15 and the outer structure assembly 13 without deflection.

[0053] In yet another embodiment, the present invention provides a device 10, wherein the material of the base pallet 1 and the holding pallet 2 is a fire retardant FR4 grade material. The base pallet 1 comprises at least 12 bearing holders 5. The outer structure assembly 11 comprises a plurality of square tubes connected by welding to form a reinforced truss structure.

[0054] In yet another embodiment, the present invention provides a device 10, wherein a poke-yoke block 7 is configured to control the reversing of the device 10.

[0055] The present invention provides several improved features and advantages, thereby solving existing problems in the field of Battery module bonding.

[0056] Precision and Accuracy: Achieving high precision and accuracy in two dimensional X and Y is critical, particularly in applications like CNC machining and Laser Bonding. It should be noted that small deviations may lead to significant errors in the final product. The manual indexing fixtures of the present invention allow for precise adjustments, ensuring the laser is aligned correctly with the bonding points. Also, the indexing fixture helps achieve repeatable positioning, leading to uniform bonding across multiple parts.

[0057] Mechanical Backlash and Play: Mechanical backlash and play in the movement mechanisms may cause inaccuracies and inconsistencies in the two-dimensional positioning of the workpiece. Backlash occurs due to gaps between moving parts, leading to a lag in response. The preload mechanism of the present invention includes dowel pins which eliminate backlash by maintaining the stability of the Battery Module.

[0058] Alignment and Calibration: Maintaining proper alignment and calibration of the X and Y axes is essential for accurate movement. Misalignment can lead to uneven wear and degraded performance.

[0059] Load Handling and Stability: Handling varying loads and ensuring stability during X and Y movements is critical, especially when working with large or heavy components. Load variations can affect accuracy and performance. Load compensation mechanisms of the present invention help to adjust the movement system based on the weight and distribution of the load through guide rails. Also the robust design and structure of the present invention support structures and guides to handle different load conditions without compromising stability.

[0060] Noise and Vibration: Excessive noise and vibration can impact the precision and lifespan of the movement system, as well as the working environment. The present invention provides vibration isolation through guide rails and bearing used for ease of movement and reduce vibration.

[0061] Integration and Control: Integrating X and Y axes movements with other system components and controlling them efficiently can be complex, especially in multi-axis systems. The present invention provides integrated control systems with manual mechanism to prevent the complex controlling on the laser bonding machine.

[0062] The present invention provides several improved features and advantages thereof, particularly, improved material handling, flexibility and adaptability, cost and space efficiency, improved ergonomics, enhanced safety, increased productivity, ease of integration, reduced downtime, scalability, etc.
[0063] While this invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims. , Claims:WE CLAIM:

1. A device 10 for adaptive laser bonding process with integrated loading and unloading systems, comprising:
an outer structure assembly 11 comprises a poke-yoke block 7, pallet rollers 8, and guides 9, wherein the device 10 is configured to slide from an input station 13 to the assembly 11 and further to an output station 14 on the guides 9 and pallet rollers 8 of the assembly 11;
a base pallet 1 comprises at least two guide rails 3 attached on upper surface and a plurality of bearing holders 5 attached on lower surface, wherein the base pallet 1 is configured to slide on the guides 9 and pallet rollers 8 of the outer structure assembly 11 in a single direction between the input 13 and output 14 stations having a gap 15 between therein, and the device 10 is configured to move smoothly between the assembly 11 and the stations 13, 14 due to chamfers 17 provided at corners of the outer structure assembly 11 and stations 13, 14; and
a holding pallet 2 comprises a plurality of guide blocks 4 on lower surface and a working area on upper surface, wherein the holding pallet 2 is configured to slide on the guide rails 3 of the base pallet 1 in a direction orthogonal to the base pallet 1.

2. The device 10 as claimed in claim 1 is an indexing pallet device, wherein the direction of the base pallet 1 is on x-axis and the direction of the holding pallet 2 is on y-axis.

3. The device 10 as claimed in claim 1, wherein the device 10 comprises a plurality of dowel bushes 6 and handles 6A, the dowel bushes 6 are attached to the holding pallet 2 to position the holding pallet 2 in the y-axis direction and the handles 6A are attached to the base pallet 1 to slide the base pallet 1 in the x-axis direction.

4. The device 10 as claimed in claim 1, wherein the plurality of bearing holders 5 in the base pallet 1 enable the device 10 to slide through the gap 15 having a width ranging from 5 mm to 20 mm between the outer structure assembly carrying the pallet device 10 and the input station 13 or the output station 14 without any deflection.

5. The device 10 as claimed in claim 1, wherein the material of the base pallet 1 and the holding pallet 2 is a fire retardant FR4 grade material.

6. The device 10 as claimed in claim 1, wherein the base pallet 1 comprises at least 12 bearing holders 5.

7. The device 10 as claimed in claim 1, wherein the outer structure assembly 11 comprises a plurality of square tubes connected by welding to form a reinforced truss structure.

8. The device 10 as claimed in 1, wherein the poke-yoke block 7 is configured to control the reversing of the device 10.