Automation of the lid assembly operation in the lead/acid automotive batteries manufacturing process

Automation of an assembly operation in the automotive lead/acid battery production line is described in the paper. The working operation-setting of the polypropylene lids on the battery containers-is automated using a small-size industrial robot. During the process of lid setting onto the battery container, it is necessary for the plate stack electrodes to slide into the hollow lead terminals of the lids. Therefore, the lid assembly operation is considered as a problem of a multiple peg-in-hole insertion. The paper presents basic principles of multiple part mating task with special regard to the lid assembly. Presented are design of the workcell peripheral devices and incorporation of the workcell into the existing automotive battery production line. Two lid feeding devices were built providing the lid storage and feeding for half an hour at a full rate of production for five different lid types. A special robot gripper intended for sensory supported lid setting strategy is also described. The presented robot workcell was successfully installed into the automotive batteries manufacturing plant and has been operating continuously in three working shifts per day for about six months.