The Industrial Challenge:Automating the assembly of EV Battery Packages is one of the highest-risk operations in modern manufacturing. The materials are hazardous (Li-Ion), the components are fragile (3D-printed prototypes), and the tolerances are near-zero (-0mm / +3mm). A single collision or handling error doesn't just mean scrap—it means critical safety failures and line stoppage.
The Mission:In this project (WorldSkills Lyon 2024 Context), I engineered a fault-tolerant robotic cell capable of handling variable battery modules, performing high-precision sealing with Remote TCP, and adapting to chaotic part feeding without operator intervention.
My Role:Not just programming, but Full Process Validation. I used Digital Twin technology to stress-test the layout, cycle time, and collision risks before the physical build, ensuring 100% feasibility from Day 0.
Why Simulation Saves Budget (The "Test Before Invest" Model)
Before touching the real robot, I built a 1:1 Digital Twin of the cell. This allowed me to:
ACC60 logic) in the virtual environment.The Bottom Line: When the physical integration started, the code was already validated. This is the core of my De-Risking Methodology.
The Risk: In high-speed assembly, a robot moving at 100% speed can destroy expensive peripherals (cameras, I/O boards) in milliseconds.The Solution: I didn't just set "safe zones". I implemented Stop Prediction logic based on inertia analysis. By force-limiting speed based on payload weight (Dynamic Payload Checker), I guaranteed that the robot physically cannot crash into the vision system, even if the code commands it to. This is Hardware Insurance via software.
The Risk: Rigid automation fails when parts arrive rotated or in unexpected orders. Retooling the line for every variation kills OEE (Overall Equipment Effectiveness).The Solution: I designed an adaptive logic using iRVision with optimized ROI (Region of Interest).
The Challenge: Applying sealant to a battery lid requires following a complex 3D contour with constant speed. Any hesitation creates bubbles (leakage risk).The Technical Edge: By using Remote TCP, I inverted the motion logic: the robot moves the part around the static tool tip.The Result: Perfect seam quality with -0mm tolerance. I utilized DISTANCE BEFORE logic to compensate for sealant gun latency, ensuring the bead starts exactly where the CAD model dictates.
.svg)
.svg)