APPARATUS FOR THE MANUFACTURE OF BATTERY COMPONENTS

Abstract

An apparatus for separating battery plates includes a work surface for receiving a stack of battery plates, and an alignment mechanism for aligning the battery plates on the work surface. The work surface is movable between a first position in which it is angled with respect to a horizontal plane and a second position in which it is substantially aligned with the horizontal plane. When the work surface moves between the first and second position adjacent battery plates of the stack are displaced relative to each other.

Claims

1-20. (canceled)

21. An apparatus for separating battery plates comprising: a work surface for receiving a stack of battery plates; a first displacement mechanism configured to shear the plates of the stack relative to each other in a first, substantially horizontal, direction; and an alignment mechanism for aligning the battery plates in a stack.

22. An apparatus according to claim 21, further comprising a second displacement mechanism configured to shear the plates of a stack relative to each other in a second direction.

23. An apparatus according to claim 22, wherein the second displacement mechanism is configured to shear the plates substantially horizontally, in a direction opposite to that caused by the first displacement mechanism.

24. An apparatus according to claim 21, further comprising a third displacement mechanism, wherein the third displacement mechanism is configured to shear the plates in a direction which is substantially perpendicular to the first direction, such that the third displacement mechanism shears the plates substantially vertically.

25. An apparatus according to claim 24, wherein the third displacement mechanism comprises a mechanism for moving the work surface between a first position in which it is angled with respect to a horizontal plane; and a second position in which it is substantially aligned with the horizontal plane.

26. An apparatus according to claim 21, wherein moving the work surface between the first and second positions causes the plates to shear vertically with respect to each other.

27. An apparatus according to claim 21, wherein the apparatus further includes a splitting mechanism, and wherein the splitting mechanism in use laterally breaks the stack of battery plates into a plurality of stacks.

28. An apparatus for processing battery plates comprising: an automatic feed mechanism for transferring an individual stack of battery plates from a supply of battery plates; a battery plate separator apparatus for receiving the stack of battery plates, the apparatus including: a work surface for receiving in use at least one stack of battery plates, a first displacement mechanism configured to shear the plates of the stack relative to each other in a first, substantially horizontal, direction; and an alignment mechanism for aligning the battery plates in a stack; and a supply mechanism for transferring a separated stack of plates for subsequent processing.

29. An apparatus according to claim 28, wherein the feed mechanism transfers the stacks of plates from the plate separator apparatus to the supply mechanism after separation.

30. An apparatus for processing battery plates according to claim 28, wherein the feed mechanism comprises a robot.

31. An apparatus for processing battery plates according to claim 30, wherein the robot is provided with a sensor for detecting the presence or position of a stack of plates for processing.

32. (canceled)

33. An apparatus for processing battery plates according to claim 28, wherein two battery plate separator apparatuses are provided; and wherein the feed mechanism is configured to simultaneously move two stacks of battery plates.

34. An apparatus for processing battery plates according to claim 31, wherein the supply of plates are provided on a pallet containing a plurality of stacks and the sensor identifies at least one datum point on the pallet.

35. A method of separating battery plates comprising: (a) moving at least one stack of battery plates with an automated feed mechanism from a supply station to a battery plate separator apparatus; the battery plate separator apparatus comprising: a work surface for receiving a stack of battery plates; a first displacement mechanism configured to shear the plates of the stack relative to each other in a first, substantially horizontal, direction; and an alignment mechanism for aligning the battery plates in a stack; (b) operating the battery plate separator apparatus to shear the plates of the stack relative to each other in a first, substantially horizontal, direction, thereby separating adjacent battery plates; (c) aligning the stack of battery plates; (d) moving the at least one stack of battery plates with an automated transfer mechanism from the battery plate separator apparatus to an end station for further processing.

36. A method according to claim 35, wherein step (a) includes pivoting an arm from a substantially vertical position to the substantially horizontal position.

37. A method according to claim 35, wherein step (a) includes dropping the least one stack of battery plates onto a work surface on the battery separator apparatus.

38. A method according to claim 35, wherein the at least one stack of battery plates is received on an inclined work surface of the battery plate separator apparatus, and step (b) includes operating the battery plate separator to move the work surface between an inclined orientation and a substantially horizontal orientation, thereby shearing the battery plates vertically relative to each other.

39. A method according claim 35, wherein step (b) includes shearing the battery plates in a second, substantially horizontal, direction, the second direction being opposite to the first direction.

40. A method according to claim 35, wherein the method further includes step (c1) splitting the stack of battery plates into a plurality of stacks if the dimensions of the stack are found to exceed set specified values.

41. A method according to claim 35, wherein step (d) includes pivoting an arm from the substantially horizontal position to the substantially vertical position to remove the one or more stacks from the battery plate separator apparatus for further processing.

42-47. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0120] Specific embodiments of the invention will now be described in detail by way of example only and with reference to the accompanying drawings in which:

[0121] FIG. 1 is a schematic representation of a plan view of an apparatus for separating battery plates according to an embodiment of the invention;

[0122] FIG. 2 is a schematic cross-sectional view, taken through line A, of a work station of the apparatus of FIG. 1, with the platform in an inclined position;

[0123] FIG. 3 is a schematic cross-sectional view, taken through line A, of a work station of the apparatus of FIG. 1, with the platform in a substantially horizontal position;

[0124] FIG. 4a is schematic plan view of a work station of the apparatus of FIG. 1 with a first displacement mechanism in its operational position, and FIG. 4b is a schematic cross-sectional view through FIG. 4a;

[0125] FIG. 5a is schematic plan view of a work station of the apparatus of FIG. 1 with a second displacement mechanism in its operational position, and FIG. 5b is a schematic cross-sectional view through FIG. 5a;

[0126] FIG. 6a is schematic plan view of a work station of the apparatus of FIG. 1 with a third displacement mechanism in its closed position, and FIG. 6b is a schematic cross-sectional view through FIG. 6a;

[0127] FIG. 7 is a plan view of a feed mechanism according to an embodiment of the invention;

[0128] FIGS. 8a, 8b and 8c are schematic side views of the feed mechanism of FIG. 7 in operational positions;

[0129] FIG. 9 is a schematic plan view of an apparatus for manufacturing battery plates according to an embodiment of the invention;

[0130] FIGS. 10a-10d are schematic side views of an apparatus for separating battery plates according to a further embodiment of the invention;

[0131] FIGS. 11a and 11b are schematic side views showing the splitting mechanism dividing a stack of battery plates in two according to an embodiment of the invention; and

[0132] FIGS. 12a-12d are schematic side views of a split stack of battery plates being unloaded from the apparatus according to an embodiment of the invention.

DESCRIPTION OF AN EMBODIMENT

[0133] FIG. 1 shows a plan view of an apparatus 100 for separating battery plates according to an embodiment of the invention.

[0134] The apparatus 100 for separating battery plates, also referred to as a battery plate separator 100 includes two work stations 110. Each work station 110 includes a platform 112 having essentially flat upper surface 114 configured to receive a stack of battery plates 10. In use, the battery plates 10 are aligned with upper edges having tabs 12 facing upwards (shown, for example in FIG. 4b) and their lower edges 14 resting on the upper surface 114.

[0135] Each work station 110 is provided with an actuator 120, which is operable to move the platform 112 between an inclined orientation (shown in FIG. 3) and a substantially horizontal orientation (shown in FIG. 3). In the embodiment shown, the platform 112 is pivotable about an axis provided towards a first side 112a of the platform 112, and an actuator 120 is provided at a second opposite side 112b. The second edge 112b of the platform is moved up and down by the actuator 120 as it moves between an extended (FIG. 2) and a retracted position (FIG. 3). A stop 116 is provided on the upper surface 114 towards the side 112b. The stop 116 acts to prevent the stack of battery plates 10 sliding off the surface 114 or moving out of essentially vertical alignment.

[0136] In other embodiments (not show), the platform is pivotable about a central axis, and actuator(s) are provided on one or both sides of the central axis. It will be appreciated that any suitable actuating mechanism can be provided which is operable to move the platform.

[0137] Each work station 110 also includes two guides 130, provided above the first and second sides of the platform, the guides 130 having essentially flat vertical inward facing surfaces, which act to guide the stacks of battery plates 10 onto the upper surface 112. It will be appreciated that the separation of the guides 130 can be adjusted as required, depending on the size of stack to be processed, i.e. the number of battery plates within a stack to be separated. The guides 130 move inwards when the platform is moved into its horizontal (as shown in FIG. 3) to provide vertical support to the battery plates during further operation of the apparatus (described in detail below). In an alternative embodiment (not shown), the guides can be fixed during operation of the work station.

[0138] Each work station 110 includes an agitator 140, which is operable to vibrate the platform 112.

[0139] Each work station 110 is provided with a first displacement mechanism 150, a second displacement mechanism 160 and an alignment mechanism 170. In the embodiment shown, these mechanisms are all provided along the axis B on third 112c and fourth 114d sides of the platform 112.

[0140] As can be seen in FIG. 4a, the first displacement mechanism 150 includes first and second opposing blocks or jaws 152, 153 which are moveable between an operational position (FIGS. 4a and 4b) and retracted position (for example in FIG. 5b). The first displacement mechanism 150 includes an actuator 154 for moving the blocks 152, 153. The first and second opposing blocks 152, 153 have opposing surfaces, which face the side edges of the battery plates loaded onto the work surface 112. The first block 153 has a projecting arrow head profile and the second block 152 has a corresponding concave arrow head shaped profile.

[0141] As can be seen in FIG. 5a, the second displacement mechanism 160 includes third and fourth opposing blocks or jaws 162, 163 which are provided below first and second blocks (of the first displacement mechanism). The first and second blocks which are moveable between an operational position (FIGS. 5a and 5b) and retracted position (for example, FIG. 4b). The mechanism 160 includes an actuator 164 for moving the blocks 162, 163. The third and fourth opposing blocks 162, 163 have opposing surfaces, which in use face the side edges of the battery plates loaded onto the work surface 112. The third block 162 has a concave arrow head shaped profile and the fourth block 162 has a corresponding projecting arrow head profile.

[0142] As can be seen in FIG. 6a, the alignment mechanism 170 includes a pair of blocks 172, 173 having opposing flat surfaces, which in use face the side edges of the battery plates in the stack 10. The alignment blocks 172, 173 are provided below the second displacement mechanism 160. The alignment blocks 172, 173 are moveable between an open position (FIG. 4a) and a closed position (FIGS. 6a and 6b) in which the blocks are spaced apart by a distance substantially equal to a battery plate width. As the alignment blocks 172, 173 move to the closed position, the battery plates in the stack 10 are pushed into alignment.

[0143] FIGS. 7 to 8c show a robot 200 which can be used to load the battery plate separator 100 described above.

[0144] The robot 200 is an articulated arm 202 having a lower section 220 and an upper section 230. The upper section 230 is rotatably attached to the lower arm 220 at 222. The robot 200 is rotatable about a base 210.

[0145] The upper section 230 includes an arm 232 and a head 230 having two grippers 240. Each gripper 240 includes a pair of opposed gripping members 242, 244 arranged in a substantially parallel alignment. Each gripper 240 includes an actuator 246 for displacing an inner gripper member 242 towards an opposing, outer gripper member 244. The inner gripping member 242 is moveable between a closed orientation, in which the gripping members securely hold a stack of battery plates 10, and an open orientation. The separation of the gripping members in the closed orientation can be programmed as necessary depending on the size of stack to be processed. Each gripper member comprises a pair of spaced jaws (not shown in figures).

[0146] FIG. 9 shows an apparatus 1 for manufacturing battery plates, including the plate separator 100, the robot 200, a pallet 300, a conveyor apparatus 400 and a further processing station 500.

[0147] In the embodiment shown, the pallet 300 includes a base 310 having a ribbed upper surface. In this embodiment the ribbed upper surface is formed by parallel cross beams 312 extending across a width or length. The cross beams 312 each have a width x are spaced apart by a distance y. The dimensions x and y are determined by the size and number of the robot gripper member, so that in use one gripping member (of an opposing pair) can be inserted into the grove/space under a stack and the pair of gripping members closed to pick the stack from the pallet.

[0148] In an alternative embodiment of a pallet (not shown), the ribbed surface is formed by parallel grooves formed in a solid surface.

[0149] In use, stacks of battery plates 10 are loaded onto the pallet 300 following the curing process. In FIG. 9, two rows of battery plate stacks 10 are shown loaded on the pallet. The stacks 10 are positioned so as to be aligned with the cross beams 312 such that the gripper mechanisms can be inserted into the grooves or spaces under each stack, allowing the gripper jaws to close around the stack.

[0150] In the embodiment the pallet has a generally square form. However it will be appreciated any suitable shape of pallet can be used, since the robot can be programmed as necessary using the datum points (corner posts and/or ribbed upper surface) to pick up the loaded stacks.

[0151] The conveyor apparatus 400 includes two conveyor belts 410 provided side by side, which extend in a generally horizontal plane. The belts 410 carry stacks of battery plates to a further processing station 500, which could be for example an enveloping machine. The conveyor apparatus 400 includes at least one cut out (not shown) under the upper section of the belt at a loading position. The cut out(s) have dimensions corresponding to the jaw(s) of the robot gripper mechanism to allow the robot to place the separated stacks of battery plates onto the conveyor belt.

[0152] In use the robot 200 rotates about its base 210 to a position adjacent to the pallet 300. The upper section 230 rotates about the point 222 to align one of the gripper mechanisms with a stack 10 on the pallet 300. The robot moves into position, the gripper mechanism 240 closes around the first stack 10 and removes the stack from the pallet. The upper section rotates 180 degrees and the arm moves to align the other gripper mechanism 240 with a second stack 10 on the pallet 300. Once the robot 200 has picked up the second stack 10 (as shown in FIG. 8a), it rotates about its base 210 to a position adjacent to the battery plate separator 100.

[0153] The robot 200 moves to position, such that each gripper 240 is positioned above the platform 112 of a work station (shown in FIG. 8b). At this stage, the platform 112 of the work station 100 is in its inclined position and the stops 130 are open. The gripper mechanism 240 opens, thereby releasing the stack which drops down onto the work surface 114. In FIG. 8b, reference 10.sup.1 shows the stack falling. The plates within the stack fall essentially vertically until they impact on the work surface (shown by reference 10.sup.2). Since the work surface 114 is inclined, the battery places move downwards by different amounts with the plate closest to the stop 116 moving furthest (FIG. 8b and FIG. 2). This means that the battery plates displace vertically with respect to their adjacent plate(s). This shearing action breaks some or all of the bonds created between plates during curing and separates the plates.

[0154] The platform 112 is then moved to its horizontal position (shown in FIGS. 3 and 8c) and the stops 130 are moved inwards. The agitator 140 operates to vibrate the platform 112.

[0155] Once the platform 112 is in its horizontal position, the first displacement mechanism 150 is operated. The first and second blocks 153, 152 move to their operational position to displace the battery plates in the stack relative to each other in a first, essentially horizontal or lateral direction (FIGS. 4a and 4b); and are then retracted. Then the second displacement mechanism 160 is operated operates to displace the plates relative to each other in an opposite lateral direction (FIGS. 4a and 4b). Finally, the alignment mechanism 170 operates to push the battery plates back into alignment to form a neat stack.

[0156] With regard to the two work stations, it will be appreciated that the robot 200 may drop both stacks of battery places simultaneously onto respective platforms 112, or the robot 200 may drop the stacks sequentially. The work stations may operate simultaneously, or independently.

[0157] As shown in FIG. 8c, once stacks of aligned, separated battery plates (shown by reference 10.sup.3) have been formed on the work stations 112, the robot 200 picks up the two stacks. It rotates about its base to a third position adjacent to the conveyor apparatus 400 and places a stack on each conveyor belt 410.

[0158] Whilst a robot with two gripper mechanisms has been described, it will be appreciated that alternative feed arrangements can be provided for use with the battery plate separator. For example the feed mechanism could be a single robot having one gripper mechanism or multiple robots (for example two) each having a single gripper mechanism. Alternatively, a feed mechanism could be provided for moving the stacks from the pallet to the battery plate separator, and a different transfer mechanism could be provided for moving the stacks from the battery plate separator to the next work station.

[0159] FIGS. 10a-10d show an apparatus 600 for separating battery plates according to a further embodiment of the invention. Where the features are the same as in previous figures, those features are given the same reference numeral except preceded with a 6.

[0160] The work surface 612 is coupled to an arm 625. The arm 625 is pivotable around an axis 627 between a substantially vertical (FIGS. 10a-b) and a substantially horizontal position (FIGS. 10c-d). FIGS. 10a and 10b show the work surface 612 being pivotable with respect to the arm 625 between a position substantially aligned with the vertical plane (FIG. 10a), and a position angled with respect to the vertical plane (FIG. 10b).

[0161] The apparatus 600 further comprises a splitting mechanism 635, which will be described in more detail in FIGS. 11a and 11b.

[0162] In use, a stack of battery plates 610 are loaded into the apparatus 600 when the arm 625 is in the vertical position, as shown in FIG. 10a. The stack of battery plates 610 are loaded into the apparatus using the robot 200 as described above with respect to FIGS. 7 to 8c. The battery plates 610 are supplied via a pallet 300, as described above.

[0163] The stack of battery plates 610 are positioned next to the work surface 612, and aligned such that the side edges of the plates 610 face the work surface 612. The stack of battery plates 610 is then clamped in place, as shown in FIG. 10b, by opposing blocks 626 in the operational position. The opposing blocks 626 comprise a first displacement mechanism 650, a second displacement mechanism 660 and an alignment mechanism 670.

[0164] Whilst the arm 625 is in the vertical position, the work surface 612 is pivoted with respect to the arm 625 from the position substantially aligned with the vertical plane to the position angled with respect to the vertical plane. The arm 625 is then pivoted around pivot point 627 from the vertical position to the horizontal position, as shown in FIG. 10c. In this position, the opposing blocks 626 are retracted slightly to release the stack of battery plates 610 such that they may fall onto the inclined work surface 612 to vertically displace adjacent battery plates relative to each other. The stack of battery plates are now in the same configuration as shown in FIG. 2, and the plate separation process continues as described in FIGS. 2-6b.

[0165] FIGS. 11a and 11b show the splitting mechanism 635 in more detail. The splitting mechanism 635 comprises a pointed or tapered rod 637 coupled to an actuator 638. In a stored position, as shown in FIG. 10a, the pointed end of the rod 637 is below and generally adjacent to the upper surface 614 of the work surface 612. The work surface 612 comprises an aperture in both the upper surface 614 and a lower surface to accommodate the rod 637.

[0166] The apparatus 600 comprises a sensor (not shown) to detect the width of the stack of battery plates 610 between the two opposing blocks 626.

[0167] In use, if the sensors detect that the width of the stack of battery plates 610 is greater than a required size (for example 150 mm), the actuator 638 is activated and extends the rod 637 upwards through the apertures in the work surface 612 and into the stack 610. FIG. 11a shows the initial contact between the pointed end of the rod 637 and the stack 610 where the rod 637 starts to displace the adjacent plates 618. It will be appreciated that depending upon the required use of the machine (for example whether it is always used to process the same type and size of battery plate) the transverse position of the rod 637 may be adjustable. For example the transverse position could be controlled by an actuator or the transverse position may be selectable during initial configuration of the apparatus.

[0168] The rod 637 is extended further upwards into the stack 610 until it is maximally extended (as shown in FIG. 11b). In this position, the stack 610 is divided into two separate stacks 610a, 610b which are both less than 150 mm wide. To accommodate the split stacks 610a, 610b and the rod 637, the opposing blocks 626 release their grip on the stack 610 and move into a partially retracted position thus allowing the two stacks to separate slightly in the lateral direction.

[0169] FIGS. 12a-12d show the split stack 610a, 610b being unloaded from the apparatus 600. In use, the opposing blocks 626 once again clamp the stacks 610a, 610b to secure them in place. The arm 625 then pivots around the pivot point 627 from the horizontal position (as shown in FIG. 12a) to the vertical position (as shown in FIG. 12b). The opposing blocks 626 move into a fully retracted position. The stack 610a falls downwards under gravity onto one of the blocks 626, and the stack 610b falls downwards under gravity onto the rod 637. The stacks 610a, 610b can now be unloaded from the apparatus 600 by hand, or alternatively via robot 200. The stacks 610a, 610b are then transferred onwards as described above to further processing station 500.

[0170] As the orientation of the unseparated stacks of plates on the pallet may not initially be correct the apparatus may further be provided with a turnover unit. The turnover unit may be a simple mechanism arranged to receive a stack of plates and reverse their orientation. The turnover unit may be associated with a detection system for monitoring the orientation of the stacks on the pallet. The detection system may be associated with a controller which may selectively utilise a gripper arm to direct required stacks to the turnover unit. After being turned by the turnover unit, the stack may be returned to the pallet or loaded into the separating apparatus. The stacks of battery plates may be supplied in one or more rows on the pallet. Preferably, each row of stacks is oriented in the same way on the pallet. If any stacks are found to be oriented differently to the others in that row, a gripper arm may transfer the stack to the turnover unit to re-orients it to match the other stacks in that row. Having all the stacks face in the same orientation helps to ensure the stacks are placed in the battery plate separator apparatus correctly and efficiently.

[0171] While the invention has been described above with reference to one or more preferred embodiments, it will be appreciated that various changes or modifications may be made without departing from the scope of the invention as defined in the appended claims.