Electric vehicles (EVs) rely on large battery packs for energy. These battery packs are often too heavy and large for conventional conveyance or manual handling. They also pose an explosion risk, so they require robotic pick-and-place equipment and specialized roller conveyors. These conveyor systems can safely, accurately, and efficiently move and stack electric vehicle battery packs without risk to human staff.
Handling EV battery packs comes with unique challenges, including weight, explosion risk, throughput speed, ergonomics, and space constraints. A conveyor system tailored to these specific needs provides a safe and efficient working environment for battery assembly and handling.
Here, we’ll explore the proper conveyor solutions for EV battery processing, considerations when specifying a conveyor for your facility, and the benefits of choosing the right conveyor system.
Conveyor Solutions for EV Battery Processing
Pack-In-Pack-Out EV battery handling conveyors are roller conveyors used to accurately pick and place incoming batteries and transfer them to the next station. These conveyors have a U-shaped design that features an incoming section on one end, a transfer section in the middle, and an outgoing section on the other end.
The pick-and-place operations happen in the transfer section, which consists of conveyors and a pop-up section where the batteries are transferred laterally by a transfer mechanism consisting of chain or belt drive. The transfer section rises to lift the batteries above the roller surface, allowing the battery to shift laterally to the outgoing section. Depending on the required transfer speed, load, and other requirements, the transfer station may be equipped with chains or belts. Finally, the transfer mechanism lowers the batteries onto the rollers of the outgoing section.
Challenges to Consider When Handling EV Batteries
Handling EV batteries comes with unique challenges, the biggest ones being the weight and size of the battery packs. Other challenges are:
- Throughput speed of the conveyor system
- Explosion risk awareness and mitigation
- Zero-pressure accumulation
- Floor design and space constraints
- Ergonomic requirements, such as proper conveyor height, to facilitate operator inspection of battery packs
- Loading and unloading methods of incoming and outgoing sections, such as cranes, forklifts, or other handling equipment
- Accuracy of the pick-and-place operation. For accurate pick and place, the batteries and conveyors may need vision markers that the robotic vision system would use to place the batteries at specific locations on the conveyor.
How Conveyor Systems Improve Efficiency
EV battery handling conveyors roller conveyor systems improve the efficiency of your EV battery handling and production process in several ways:
- Saves Space: The U-shape of the roller conveyor system and the high lift function of the transfer section help conserve floor space. Turntable conveyors can further minimize occupied real estate.
- Safe, Quick, Unsupervised Handling: Pack-In-Pack-Out conveyors for EV handling allow for efficient, accurate pick-and-place positioning and stacking without operator supervision.
- Minimal Downtime: These battery conveyor systems reduce operator intervention and system downtime, boosting overall output.
- Low Maintenance: Pack-In-Pack-Out conveyors are low maintenance, requiring only lubrication of the drive chains and inspection for wear throughout service.
MC3 Conveyor Offerings Can Help With EV Battery Handling
Electric vehicle battery packs are too heavy to lift manually and can present a risk of explosion. EV battery handling roller conveyor systems and pick-and-place robots are the ideal solutions for assembling and handling battery packs while protecting workers. These conveyors have a U-shape with a transfer section for moving incoming battery packs to an outgoing section with high precision and efficiency. The conveyor systems optimize floor space with their unique shape, allowing for installation in confined spaces.
MC3 Manufacturing is a custom conveyor system fabricator, providing EV battery conveyor systems designed to save space, improve safety, and enhance process efficiency. Contact us or request a quote to speak with a specialist about your EV battery handling solutions.