STACK MANIPULATING SYSTEM AND CORRESPONDING METHOD

Abstract

The present invention relates to a stack manipulating system configured to move a stack of plates, in particular lead battery plates, from at least one arrival location to at least one target location at a machine where the plates are to be processed, and wherein the stack manipulating system comprises: — a first zone comprising the at least one arrival location and a non-static moving assembly having a range of motion, wherein the complete range of motion is located within the first zone, — a second zone comprising the at least one target location and the machine, wherein the second zone is configured to accommodate an operator, - a separation, separating the second zone from the first zone, the separation being configured for preventing the operator to move into the first zone, - at least one conveyor traversing the separation, the at least one conveyor comprising an entrance in at least one intermediate location located in the first zone and an exit located in the second zone, wherein the conveyor defines a trajectory between the entrance and the exit and comprises a guide structure which extends between the entrance and the exit along said trajectory and which guides the stack of plates along said trajectory, and wherein, at least in the second zone, the guide structure is a static structure, wherein the moving assembly comprises moving parts, and wherein the moving parts are configured to stay outside the second zone.

Claims

1. A stack manipulating system configured to move a stack of plates, in particular lead battery plates, from at least one arrival location to at least one target location at a machine where the plates are to be processed, and wherein the stack manipulating system comprises: a first zone comprising the at least one arrival location and a non-static moving assembly having a range of motion, wherein the complete range of motion is located within the first zone, a second zone comprising the at least one target location and the machine, wherein the second zone is configured to accommodate an operator, a separation, separating the second zone from the first zone, the separation being configured for preventing the operator to move into the first zone, at least one conveyor traversing the separation, the at least one conveyor comprising an entrance in at least one intermediate location located in the first zone and an exit located in the second zone, wherein the conveyor defines a trajectory between the entrance and the exit and comprises a guide structure which extends between the entrance and the exit along said trajectory and which guides the stack of plates along said trajectory, and wherein, at least in the second zone, the guide structure is a static structure, wherein the moving assembly comprises moving parts, and wherein the moving parts are configured to stay outside the second zone.

2. The stack manipulation system according to claim 1, wherein the moving assembly comprises a moveable manipulator, wherein the moveable manipulator comprises an engagement member which is configured to engage the stack of plates in the at least one arrival location, and wherein the moveable manipulator is configured to move the stack of plates from the at least one arrival location to the at least one intermediate location.

3. The stack manipulation system according to claim 1, wherein the at least one intermediate location is located at a first vertical distance from the at least one arrival location and at a second vertical distance from the at least one target location, wherein the moving assembly is configured to move a stack of plates over the first vertical distance to the at least one intermediate location, and wherein the at least one conveyor is configured to move the stack of plates over the second vertical distance to the at least one target location, wherein the moving assembly and the at least one conveyor work together to move the stack of plates past the separation and towards the machine.

4. The stack manipulation system according to claim 1, comprising at least one plate loosening device, configured to loosen the plates of a stack, wherein the at least one plate loosening device comprises: a bottom wall configured to support a stack of plates, at least one guide body, wherein the guide body is moveably connected to the bottom wall, and being configured to abut against the stack of plates, a guide body drive system being connected to the at least one guide body and comprising at least one actuator configured to move the at least one guide body, wherein the guide body drive system is configured to move the at least one guide body to pivot the stack of plates over an angle with respect to a neutral position, wherein the movement of the at least one guide body pivots the plates of the stack of plates, shearing the plates with respect to each other, wherein the plate loosening device is located at the entrance or at the exit of the at least one conveyor.

5. The stack manipulation system according to claim 3, comprising a plate loosening device comprising a wall, wherein an actuator and a guide body accelerate and/or decelerate the stack of plates against the wall, in particular the actuator and the guide body are configured to separate the plates of a stack by letting the stack fall freely on the wall.

6. The stack manipulation system according to claim 4, wherein the plate loosening device is located at the entrance or at the exit of the at least one conveyor.

7. The stack manipulation system according to claim 1, wherein the moving assembly comprises a robot arm and the conveyor does not comprise a robot arm.

8. The stack manipulation system according to claim 1, wherein the moving assembly comprises a crane.

9. The stack manipulation system according to claim 1, wherein the guide structure comprises one or more tracks or a conveyor belt.

10. The stack manipulation system according to claim 1, wherein the moving assembly and/or the conveyor comprises at least one rotational manipulator which provides at least one rotary degree of freedom for the stack of plates, wherein the at least one rotational manipulator is rotatable to change the orientation of a stack of plates between the arrival location and the target location.

11. The stack manipulation system according to claim 2, further comprising a support body and a stack of plates located at the arrival location, wherein the support body defines a plurality of longitudinal and lateral slots in an upper surface to accommodate the moveable manipulator, allowing the manipulator to reach underneath a stack that is positioned on the body, wherein the width of the slots is larger than the width of the moveable manipulator.

12. The stack manipulation system according to claim 2, wherein the support body comprises at least one recessin the upper surface other than the longitudinal and lateral slots and the moveable manipulator comprises at least one extending member, wherein the length and width of the at least one recess are larger than the length and width of the at least one extending member, wherein the moveable manipulator is configured to engage the support body at least through the at least one recess to move the support body from an arrival position to a support body storage position.

13. The stack manipulation system according to claim 1, wherein the at least one conveyor comprises an elevator and the intermediate location is located at an upper extremity or at a lower extremity of the guide structure and the target location is located at an opposite extremity of the guide structure, wherein the elevator travels along the guide structure.

14. The stack manipulation system according to claim 13, wherein the elevator is driven by an elevator system to separate the plates of a stack by accelerating and/or decelerating the stack of plates against a fixed structure, in particular the elevator system being configured to separate the plates of a stack by letting the stack fall freely on a bottom wall.

15. The stack manipulation system according to claim 1, wherein the at least one conveyor comprises at least one actuator and at least one intermediate body, wherein the at least one actuator and the at least one intermediate body are configured to move a stack of plates from the at least one intermediate location into the at least one conveyor and/or to move the stack of plates out of the at least one conveyor.

16. The stack manipulation system according to claim 1, wherein the separation comprises a protection fence with overhang, wherein the protection fence with overhang creates an area below the overhang in the second zone to accommodate the operator, wherein the moving assembly and the conveyor are configured to move the stack of plates over the protection fence.

17. The stack manipulation system according to claim 1, wherein the separation comprises a floor of a building, wherein the first zone is located on the floor of the building and the second zone is located on a lower floor of the building, or wherein the separation comprises a floor of a building, wherein the second zone is located on the floor of the building and the first zone is located on a lower floor of the building.

18. The stack manipulation system according to claim 1, wherein the machine is a battery plate arranging device, the battery plate arranging device comprising at least a first target location for a stack of battery plates of a first kind and a second target location for a stack of battery plates of a second kind, wherein the battery plate arranging device comprises a first positioning assembly and a second positioning assembly that alternatively position battery plates of the first kind and the second kind behind each other, creating a stack of alternating battery plates of the first kind and plates of the second kind, wherein the machine comprises a conveyor configured to move a stack of alternating battery plates out of the machine after having been arranged to be installed in a battery.

19. A method for manipulating a stack of plates configured to move a stack of plates, in particular lead battery plates, from at least one arrival location to at least one target location at a machine, and wherein the stack manipulating system comprises: a first zonecomprising the at least one arrival location and a moving assemblyand a complete range of motion of the moving assembly, a second zonecomprising the at least one target location and the machine, wherein the second zone is configured to accommodate an operator, a separation, separating the first zone from the second zone, the separation being configured for preventing the operator to move into the first zone, at least one conveyor extending through or over the separation, the at least one conveyor comprising an entrancein at least one intermediate location and an exitlocated at the at least one target location, wherein the intermediate location is located in the first zone, wherein the conveyor defines a trajectory between the entrance and the exit and comprises a guide structure which extends between the entrance and the exit along said trajectory and which guides the stack of plates along said trajectory, and wherein, at least in the second zone, the guide structure is a static structure, the method comprising the steps: a) engaging the stack of plates with the moving assembly in the at least one arrival location in the first zone, b) moving the stack of plates from the at least one arrival location to the at least one intermediate location in the first zone with the moving assembly, c) moving the stack of plates from the at least one intermediate location to the at least one target location in the second zone with the at least one conveyor, wherein the moving assembly comprises moving parts, and wherein the moving parts stay outside the second zone.

20. The method for manipulating a stack of plates according to claim 19, wherein the moving assembly comprises a moveable manipulator, wherein the moveable manipulator comprises an engagement member which, during step a), engages the stack of plates in the at least one arrival location, and wherein, during step b), the moving assembly moves the stack of plates from the at least one arrival location to the at least one intermediate location.

21. The method for manipulating a stack of plates according to claim 19, wherein the at least one intermediate location is located at a first vertical distance from the at least one arrival location and a second vertical distance from the at least one target location, wherein during step b) the moving assembly moves a stack of plates over the first vertical distance to the at least one intermediate location, and wherein during step c) the at least one conveyor moves the stack of plates over the second vertical distance to the at least one target location, wherein the moving assembly and the at least one conveyor work together to move the stack of plates past the separation and towards the machine.

22. The method for manipulating a stack of plates according to claim 19, wherein the stack manipulation system comprises at least one plate loosening device, wherein the plate loosening device loosens the plates of a stack from each other before arriving at the at least one target location, wherein the at least one plate loosening device comprises a guide body drive system and at least one guide body.

23. The method for manipulating a stack of plates according to claim 19, wherein the moving assembly comprises a robot arm and the conveyor does not comprise a robot arm.

24. The method for manipulating a stack of plates according to claim 19, wherein the moving assembly and/or the conveyor comprises at least one rotational manipulator which provides at least one rotary degree of freedom, wherein the moving assembly and/or the conveyor changes the orientation of a stack of plates after engaging the stack of plates.

25. The method for manipulating a stack of plates according to claim 19, wherein the at least one conveyor comprises an elevator and the intermediate location is located at a lower extremity of the guide structure and the target location is located at an upper extremity of the guide structure.

26. The method for manipulating a stack of plates according to claim 19, wherein the separation is an elongated structure creating a safe side in the second zone which is configured to accommodate an operator and to keep the operator safe from moving parts, the safe side corresponding to the second zone.

27. The method for manipulating a stack of plates according to claim 19, wherein the machine is a battery plate arranging device, the battery plate arranging device comprising at least a first target location for a stack of plates of a first kind and a second target location for a stack of plates of a second kind, wherein the battery plate arranging device comprises a first positioning assembly and a second positioning assembly that alternately position plates of the first kind and the second kind behind each other, creating a stack of alternating plates of the first kind and plates of the second kind, wherein the machine comprises a conveyor that moves the stack of alternating plates out of the machine after having been arranged to be installed in a battery.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0073] FIGS. 1A and 1B depict an embodiment of the invention in two different positions in isometric view.

[0074] FIGS. 2A-2D depict top views and side views of an embodiment of the invention in two different positions.

[0075] FIGS. 3A-3D show different views of an embodiment of the conveyor.

[0076] FIGS. 4A-4L show various positions of various components of an embodiment, depicting a process according to an embodiment.

[0077] FIG. 5 shows another embodiment of the invention in isometric view.

[0078] FIG. 6 shows another embodiment of the invention in isometric view.

[0079] FIGS. 7A-7C show an embodiment of a support structure and pallet in isometric view.

[0080] FIGS. 8A and 8B shows two embodiments of a pallet transport assembly in isometric view.

DETAILED DESCRIPTION OF THE FIGURES

[0081] FIGS. 1A, 1B, 2A, 2B, 2C, and 2D depict different views of an embodiment of a stack manipulating system 10 configured to move a stack of plates 2 from an arrival location 16A, 16B to a target location 17A, 17B, 17C at a machine 80 where the plates of the stack of plates will be processed.

[0082] The depicted machine 80 is a so-called sandwich machine that is configured to rearrange stacks of plates 2 into alternating positive and negative plates before feeding the alternating plates into a housing. Two types of plates are required for each battery; positive and negative plates. They are positioned in the housing in an alternating configuration, wherein each positive plate is sandwiched between two negative plates and vice versa. The machine 80 receives a stack of positive plates and a stack of negative plates and rearranges a number of positive and negative plates into the “sandwich-configuration” prior to placement in the housing. A different type of plates must arrive at each target location 17A, 17B, 17C for the machine 80 to be able to create the desired, rearranged sandwiches of plates.

[0083] The positive and negative plates also arrive at different arrival locations 16A, 16B. This reduces the complexity of the movement of the moving assembly and reduces the chances of errors occurring due to the placement of one type of plates at the wrong target location 17A, 17B, 17C at the machine 80.

[0084] A first zone 12 is shown comprising arrival locations 16A, 16B and a moving assembly 20. In the arrival location 16A, 16B a stack of plates 2 is located on a support body 60. The complete range of motion of the moving assembly 20 is located in the first zone 12. An operator may not be present in the first zone when the moving assembly 20 is in an operational state. In this embodiment, the moving assembly comprises a robot arm 22 comprising multiple rotational manipulators that provide a rotary degree of freedom for the stack of plates.

[0085] A second zone 14 is shown comprising target locations 17A, 17B, 17C and the machine 80. An operator is free to safely move around in the second zone, because a separation 30 separates the first zone 12, comprising the moving assembly, from the second zone 14. In the depicted embodiment, the separation 30 comprises a fence with overhang 32, wherein the second zone 14 comprises the area below the overhang. Herein, the fence with overhang 32 is the part between the area below the overhang and the first zone.

[0086] The separation may comprise a second fence (not depicted) on the side of the second zone, wherein an operator may move in the area below the overhang between the fence with overhang and the second fence, and wherein the operator may move between the second zone around the machine and the second zone in the area below the overhang. The fence with overhang and the second fence may comprise wire fencing, plate fencing, or a different type of fencing. In the figures, the fence is depicted as see-through. Additionally, the separation 30 may comprise a blockable passage, for example a door. In that way, when the moving assembly is idle, an operator may freely move between the first zone 12 and the second zone 14.

[0087] In order for a stack of plates to be moved between an arrival location 16A, 16B and a target location 17A, 17B, 17C, conveyors 40A, 40B (depicted in FIG. 5), 40C traverse the separation.

[0088] FIGS. 3A-3D shows the conveyor in greater detail.

[0089] Each conveyor (generally denoted by 40, and in particular 40C in FIG. 3D).comprises an entrance 401 that is located in an intermediate location 18A, 18B, 18C (depicted in FIGS. 1 and 2) that is located in the first zone 12 and an exit 402 that is located in the second zone 14. The conveyor defines a trajectory between the entrance 401 and the exit 402 and comprises a guide structure 42 which extends between the entrance and the exit along the trajectory. The guide structure 42 guides the stack of plates along said trajectory and is a static structure in the second zone 14. In this embodiment, the conveyor does not comprise a robot arm. In this embodiment, a plate loosening 50 is located at the entrance 401 of the conveyor, it will be understood that the plate loosening device may also be located at the exit 402 of the conveyor.

[0090] Referring to FIGS. 2A-2D, in the depicted embodiment, the intermediate location 18C is located at a first vertical distance 102 from the arrival location 16B and at a second vertical distance 104 from the target location 17C. The robot arm 22 is configured to move a stack of plates 2 over the first vertical distance 102 to the intermediate location 18C and the conveyor 40C is configured to move the stack of plates over the second vertical distance to 104 the target location 17C. Herein, the moving assembly and the at least one conveyor work together to move the stack of plates past the separation and towards the machine. This movement is shown in FIGS. 2A-2D, wherein FIGS. 2A and 2B show the situation wherein the stack of plates is engaged in the arrival location 16B and FIGS. 2C and 2D shows the situation wherein the stack of plates has been moved to the intermediate location 18C. Hereafter, the conveyor 40C will move the stack over the second vertical distance 104 towards the machine 80.

[0091] To this end, the conveyor 40 comprises an elevator 44. The intermediate location is located at an upper extremity 422 of the guide structure 42 comprising a track and the target location 17A, 17B, 17C is located at an opposite extremity of the guide structure.

[0092] To move a stack of plates into the elevator 44 the conveyor 40 comprises an actuator 46A and an intermediate body 48A (shown in FIG. 3D). The actuator 46A and the intermediate body 48A are configured to move a stack of plates 2 from the intermediate position 18 into the conveyor.

[0093] FIGS. 4A-4L depict the step-by-step process of a stack being manipulated between an arrival location 16A, 16B and a target location 17A, 17B, 17C from different views.

[0094] FIG. 4A shows a stack of plates 2 located on a support body 60 being engaged by a moveable manipulator 24 of the robot arm 22 of the moving assembly 20. In particular, the stack of plates 2 is being clamped by the extending member 242. The support bodies 60 and the stacks of plates 2 are supported by a pallet 72.

[0095] Turning to FIG. 4B, the moving assembly has moved the stack of plates 2 to the intermediate location 18. The orientation of the stack of plates 2 has changed and the moveable manipulator 24 is now positioned below the stack of plates. It is noted that the moveable manipulator 24 may also be positioned at different locations with respect to the stack of plates. The stack of plates 2 is being placed in the plate loosening device 50 while the elevator 44 is ready to receive the stack of plates 2. The plate loosening device is depicted in an open state to allow the placement of the stack of plates in the plate loosening device.

[0096] Turning to FIG. 4C, the plate loosening device 50 is depicted in a closed state, wherein actuators 57 have closed the plate loosening device, engaging the stack of plates 2. In this embodiment, the plate loosening device 50 comprises guide bodies 54 and corresponding actuators 56. While the stack of plates is supported by the bottom wall 52, the actuator 56 drives the guide body 54 and moves the guide body 54 to pivot the stack of plates over an angle α with respect to a neutral position. The movement of the guide bodies 54 pivots the plates of the stack of plates 2, shearing the plates with respect to each other and thereby loosening them. Stopping bodies 59 (depicted in FIG. 4B) are located near the bottom wall, wherein the stopping bodies restrict the movement of the stack of plates in the plate loosening device when the plate loosening device is in the closed state.

[0097] Turning to FIG. 4D, an intermediate body 48A and a corresponding actuator 46A have engaged a stack of plates 2 that has been loosened and the intermediate body 48A and actuator 46A are ready to move the stack of plates into the elevator 44. The plate loosening device is shown in the open state.

[0098] In FIG. 4E, the view has been rotated 180 degrees and the intermediate body 48A and the actuator 46A have moved the stack of plates into the elevator 44.The elevator 44 is located at the upper extremity 422 of the guide structure 42.

[0099] Moving to FIG. 4F, the view has been rotated clockwise 90 degrees and the exit 402 of the conveyor 40 is shown. The elevator 44 is now located at the lower extremity 424 of the guide structure 42 and the target location 17 is depicted. Here, two stacks of plates 2 are already being fed to the machine 80 and are kept in place by a filler assembly 47.

[0100] FIGS. 4G and 4H show the same situation seen from two different views. The stack of plates 2 is still located in the conveyor at the lower extremity of the guide structure 42. A second intermediate body 48B and a second actuator 46B have engaged the stack of plates 2 and are ready to move the stack of plates out of the conveyor.

[0101] FIGS. 4I and 4J show the same situation seen from two different views. The stack of plates has been moved out of the conveyor by the second intermediate body 48B and the second actuator 46B but has not yet been engaged by the filler assembly 47.

[0102] FIGS. 4K and 4L show the same situation seen from two different views. The filler assembly 47 has engaged the stack of plates 2 and can now feed the plates to the machine 80. The plates of the stacks of plates are oriented on edge when being fed to the machine. In FIG. 4K, part of the conveyor is omitted from the drawings in order to better be able to view the filler assembly 47.

[0103] FIG. 5 depicts another embodiment of the invention wherein the first zone 12 and the second zone 14 are located on different floors of a building. In the depicted embodiment, the first zone 12 comprises the arrival location 16A, 16B, the moving assembly 20 and its range of motion, the intermediate location 18A, 18B, 18C, and the support bodies 60 supported by the pallet 72. The second zone 14 comprises the machine 80, the target location 17A, 17B, 17C and is located on a floor that is higher than the floor where the first zone is located. In this embodiment the first zone 12 is separated from the second zone 14 by a floor of a building. Herein, the separation 30 comprises the ceiling of the floor where the first zone 12 is located, i.e. the floor where the second zone 14 is located.

[0104] By placing the arrival location on another floor than the machine, the arrival location may be approached from all directions instead of only from one side. The latter being the case when the arrival location and the machine are on the same floor.

[0105] Turning to FIGS. 6 and 7, the stack manipulation system 10 as a whole is shown and a more detailed view of a pallet 72 with stacks of plates 2 and support bodies 60 is shown.

[0106] In this embodiment, the moveable manipulator 24 is configured to engage the support body 60 through a recess 64 to move the support body from an arrival position 16B to a support body storage position 66.

[0107] FIGS. 7A-7C show how the stacks of plates 2 arrives in the arrival location 16A, 16B. A first support body 60 is located on a pallet 72 and multiple stacks of plates 2 are located on said support body 60. On those stacks of plates 2, another support body 60 is located that in turn supports multiple stacks of plates 2. The depicted support body comprises lateral and longitudinal slots 62 that are dimensioned to accommodate the moveable manipulator, and in particular the extending member of the moveable manipulator. FIG. 7C shows the support body 60 standing alone and also depicts two recesses 64A, 64B wherein the length and width of the at least one recess are larger than the length and width of the at least one extending member. This way, the extending member can engage the support body 60 in order to move it to the support body storage position. It will be understood that various other ways of engagement are possible such as, but not limited to, a vacuum gripper or a clamping assembly.

[0108] FIGS. 8A and 8B depict different embodiments of the invention, wherein the stack manipulation system further comprises a pallet transport assembly 70. FIG. 8A depicts a pallet transport assembly 70A, 70B where a pallet 72 supports stacks of plates in the arrival position 16A, 16B. The pallet transport assembly 70A, 70B comprises a pallet conveyor 74A, 74B configured to move pallets to and away from the arrival location. The pallets 72 with stacks of plates 2 move towards the arrival location 16A, 16B in the pallet conveyor 74A, 74B and the empty pallets 72 move away from the arrival location 16A, 16B in the opposite direction of their arrival and move over the pallets with stacks of plates.

[0109] The embodiment depicted in FIG. 8B shows a pallet transport assembly 70 where a pallet 72 supports stacks of plates in the arrival position 16A, 16B. The pallet transport assembly comprises a pallet conveyor 74 configured to move pallets to and away from the arrival location. The pallets 72 with stacks of plates 2 move towards the arrival location 16A, 16B in the pallet conveyor 74 and the empty pallets 72 move away from the arrival location 16A, 16B in a direction orthogonal to the arrival directions.

[0110] In an embodiment of the invention, the depicted machine is a battery plate arranging device, the battery plate arranging device comprising at least a first target location 17A for a stack of plates of a first kind and a second target location 17B for a stack of plates of a second kind.

[0111] The terms “a” or “an”, as used herein, are defined as one or more than one. The term plurality, as used herein, is defined as two or more than two. The term another, as used herein, is defined as at least a second or more. The terms including and/or having, as used herein, are defined as comprising i.e., open language, not excluding other elements or steps.

[0112] Any reference signs in the claims should not be construed as limiting the scope of the claims or the invention. It will be recognized that a specific embodiment as claimed may not achieve all of the stated objects.

[0113] The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage.

[0114] White lines between text paragraphs in the text above indicate that the technical features presented in the paragraph may be considered independent from technical features discussed in a preceding paragraph or in a subsequent paragraph.