An Application of Physical Flexibility and Software Reconfigurability for the Automation of Battery Module Assembly

Kaniappan Chinnathai, M., Günther, T., Ahmad, M., Stocker, C., Richter, L., Schreiner, D., Vera, D., Reinhart, G. and Harrison, R. 2017. An Application of Physical Flexibility and Software Reconfigurability for the Automation of Battery Module Assembly. 50th CIRP Conference on Manufacturing Systems. Taichung City, Taiwan 03 - 05 May 2017 Elsevier. https://doi.org/10.1016/j.procir.2017.03.128

TitleAn Application of Physical Flexibility and Software Reconfigurability for the Automation of Battery Module Assembly
AuthorsKaniappan Chinnathai, M., Günther, T., Ahmad, M., Stocker, C., Richter, L., Schreiner, D., Vera, D., Reinhart, G. and Harrison, R.
TypeConference paper
Abstract

Batteries are a strategic technology to decarbonize conventional automotive powertrains and enable energy policy turnaround from fossil fuels to renewable energy. The demand for battery packs is rising, but they remain unable to compete with conventional technologies, primarily due to higher costs. Major sources of cost remain in manufacturing and assembly. These costs can be attributed to a need for high product quality, material handling complexity, uncertain and fluctuating production volumes, and an unpredictable breadth of product variants. This research paper applies the paradigms of flexibility from a mechanical engineering perspective, and reconfigurability from a software perspective to form a holistic, integrated manufacturing solution to better realize product variants. This allows manufacturers to de-risk investment as there is increased confidence that a facility can meet new requirements with reduced effort, and also shows how part of the vision of Industry 4.0 associated with the integration and exploitation of data can be fulfilled. A functional decomposition of battery packs is used to develop a foundational understanding of how changes in customer requirements can result in physical product changes. A Product, Process, and Resource (PPR) methodology is employed to link physical product characteristics to physical and logical characteristics of resources. This mapping is leveraged to enable the design of a gripper with focused flexibility by the Institute for Machine Tools and Industrial Management (iwb) at the Technical University of Munich, as it is acknowledged that mechanical changes are challenging to realize within industrial manufacturing facilities. Reconfigurability is realised through exploitation of data integration across the PPR domains, through the extension of the capabilities of a non-commercial virtual engineering toolset developed by the Automation Systems Group at the University of Warwick. The work shows an “end-to-end” approach that practically demonstrates the application of the flexibility and reconfigurability paradigms within an industrial engineering context.

Year2017
Conference50th CIRP Conference on Manufacturing Systems
PublisherElsevier
Publisher's version
License
CC BY-NC-ND 4.0
File Access Level
Open (open metadata and files)
Publication dates
Published07 Jun 2017
JournalProcedia CIRP
Journal citation60, pp. 604-609
ISSN2212-8271
Book titleComplex Systems Engineering and Development Proceedings of the 27th CIRP Design Conference Cranfield University, UK 10th – 12th May 2017
Digital Object Identifier (DOI)https://doi.org/10.1016/j.procir.2017.03.128
Web address (URL)http://www.scopus.com/inward/record.url?eid=2-s2.0-85028666304&partnerID=MN8TOARS

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