New EV module manufacturing process to reduce part failures, increase efficiency
Kinemetrix says it has developed process technologies and a scalable approach to manufacturing lines aimed at meeting the growing production needs of current and future electric vehicle (EV) programs.
Its Agile3D CopperWeld process reportedly reduces part failures while increasing quality and efficiency. The process technology combines 3D vision and TIG welding for joining the small copper leads present in EV components. This technology is used for both guidance and verification of the process.
Machine vision finds the leads in three-dimensional space, verifies suitability for welding, and guides the robot to the optimal weld position. This reduces, or eliminates, failures that can scrap an expensive part, such as arc-start failures, stray arcs, and off-center welds. After welding, the same vision hardware is used to inspect the joint. A three-dimensional image of the joint is compared against quality criteria to ensure a conforming weld.
A 7th axis is added to allow for a fast dispensing. A form in place gasket (FIPG) solution with high levels of process control is provided. Kinemetrix integrates a robot servo motor into the dispensing head. Controlled as a robot 7th axis, dispensing volumes are tightly coupled to robot speeds.
Kinemetrix uses machine vision in FIPG to locate the gasket flange in three-dimensional space. The combination of servo-controlled dispense volumes and vision guidance creates a dispensing process that can consistently maintain bead width, height, and location on narrow, complex flanges.
Visit https://kinemetrix.com/expertise/electric-vehicles/ for more information.