Intelligent preparation device for film material

Abstract

The utility model provides a kind of membrane material intelligent preparation device.The utility model includes raw material dissolving unit, casting solution refining unit, membrane material preparation unit, online quality inspection unit and packaging unit, the raw material dissolving unit includes automatic metering sampling device and reaction kettle, the discharge port of automatic metering sampling device is communicated with the feed inlet of reaction kettle, stirring device is installed in reaction kettle, and monitoring device is installed on reaction kettle body;The casting solution refining unit includes filter device and vacuum centrifugal defoaming machine, the material of the discharge port of reaction kettle is received by transfer mechanism in the feed inlet of filter device, and the discharge port of filter device is connected with vacuum centrifugal defoaming machine;The membrane material preparation unit includes coating machine, and the material exported from the outlet of vacuum centrifugal defoaming machine is transferred to the casting solution inlet of coating machine by transfer mechanism.The utility model is high in intelligent degree, and the uniformity of prepared membrane material is improved.

Description

Technical Field

[0001] This utility model relates to the field of membrane material preparation technology, and in particular to an intelligent membrane material preparation device. Background Technology

[0002] In flow batteries, membrane materials are a crucial component, accounting for a significant proportion of the battery cost. Therefore, mass production technology for membrane materials is essential for the large-scale development of flow batteries. Currently, the membranes used in large-scale flow battery systems are mostly imported materials, and this technology has been dominated by foreign markets for many years.

[0003] As a key component of large-scale energy storage technology, the performance of the membrane material, the core material of flow batteries, directly affects battery efficiency. Current membrane material preparation methods largely rely on manual weighing, transfer, and quality inspection, which presents the following problems: manual operation leads to low accuracy in raw material proportioning and poor membrane material uniformity; the connection between various processes depends on manual transfer, resulting in low production efficiency. Utility Model Content

[0004] To address the aforementioned technical problems, an intelligent membrane material preparation device is provided. Through the integration of automated units, this device solves the problems of excessive manual intervention, low efficiency, and poor consistency in existing technologies. The technical means employed in this invention are as follows:

[0005] An intelligent membrane material preparation device includes a raw material dissolution unit, a casting solution refining unit, a membrane material preparation unit, an online quality inspection unit, and a packaging unit. These units are connected sequentially via pipelines or mechanical conveying structures.

[0006] The raw material dissolving unit includes an automatic metering and injection device and a reaction vessel. The outlet of the automatic metering and injection device is connected to the inlet of the reaction vessel. A stirring device is installed inside the reaction vessel, and a monitoring device is installed on the reaction vessel body.

[0007] The casting solution refining unit includes a filtration device and a vacuum centrifugal degassing machine. The inlet of the filtration device receives the material from the outlet of the reactor through a transfer mechanism, and the outlet of the filtration device is connected to the vacuum centrifugal degassing machine.

[0008] The membrane material preparation unit includes a coating machine, which transfers the material output from the vacuum centrifugal degassing machine to the casting liquid inlet of the coating machine via a transfer mechanism.

[0009] The online quality inspection unit includes a substrate inspection device, a finished film inspection device, and a laser marking machine. The substrate inspection device is installed at the substrate inlet of the coating machine, and the finished film inspection device and the laser marking machine are installed sequentially at the discharge end of the coating machine.

[0010] The packaging unit is used to package the finished film.

[0011] Furthermore, the automatic metering and feeding device includes a solid raw material metering hopper, a liquid raw material metering tank, and a feeding device. The outlets of the solid raw material metering hopper and the liquid raw material metering tank are respectively connected to the reaction vessel through the corresponding feeding devices. Both the metering hopper and the metering tank are equipped with weight sensors.

[0012] Furthermore, the reactor is a jacketed reactor, wherein the jacket is connected to a heating medium source via a pipeline.

[0013] Furthermore, the monitoring device installed on the reactor body includes a temperature sensor, a pressure sensor, a liquid level sensor, and a torque sensor.

[0014] Furthermore, the filtration device is at least a two-stage filtration device. The inlet of the first-stage filtration device is used to receive the material output from the outlet of the reactor. The two-stage filtration devices are connected in series. The outlet of the second-stage filtration device is connected to the inlet of the vacuum centrifugal degassing machine through an automatic transfer device. The vacuum centrifugal degassing machine is equipped with a vacuum centrifugal degassing machine pressure sensor.

[0015] Furthermore, the filtration accuracy of the primary filtration device is at least 5 μm, and the filtration accuracy of the secondary filtration device is at least 1 μm. Both filtration devices include a filter chamber and a removable filter membrane.

[0016] This utility model has the following advantages:

[0017] 1. The automatic metering and feeding component of the raw material dissolution unit effectively controls the accuracy of raw material addition through solid metering hoppers, liquid metering tanks and weight sensors, solving the problem of large errors in manual weighing and improving the uniformity of membrane materials.

[0018] 2. The automatic transfer component of the casting solution refining unit enables seamless connection between filtration and degassing processes, shortens the time for a single transfer, and allows the substrate conveying robot and casting solution transfer robot of the membrane material preparation unit to operate synchronously, increasing the effective daily membrane production time and solving the problem of time-consuming manual transfer.

[0019] 3. The process of membrane material preparation has greatly reduced the impact of human intervention, resulting in better uniformity of the membrane material. The entire membrane preparation process is carried out with intelligent technology, which greatly improves production efficiency and provides a foundation for the large-scale development of flow batteries. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0021] Figure 1 This is a schematic diagram of the working process of the intelligent preparation device of this utility model.

[0022] Figure 2 This is a system diagram of the present utility model.

[0023] In the diagram: 1. Solid raw material metering hopper; 2. Liquid raw material metering tank; 3. Reactor; 4. Jacket; 5. Transfer robot; 6. Primary filtration device; 7. Secondary filtration device; 8. Vacuum centrifugal degassing machine; 9. Coating machine; 10. AGV vehicle. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0025] like Figure 1 , Figure 2 As shown in the figure, this utility model embodiment discloses an intelligent membrane material preparation device, including a raw material dissolution unit, a casting solution refining unit, a membrane material preparation unit, an online quality inspection unit, and a packaging unit. Each unit is connected sequentially via pipelines or mechanical conveying structures. Furthermore, this embodiment provides the specific models of the devices used.

[0026] The raw material dissolving unit includes an automatic metering and injection device and a reaction vessel. The outlet of the 7ME6140 electromagnetic flowmeter automatic metering and injection device is connected to the inlet of the reaction vessel. A stirring device is installed inside the reaction vessel, and a visual monitoring device is installed on the reaction vessel body.

[0027] The casting solution refining unit includes a microporous ceramic membrane filtration device and an AD-10LA vacuum centrifugal degassing machine. The inlet of the filtration device receives the material from the outlet of the reactor through a transfer mechanism, and the outlet of the filtration device is connected to the TN-JB60 vacuum centrifugal degassing machine.

[0028] The membrane material preparation unit includes a GY-TBA1012 coating machine, which transfers the material output from the AD-10LA vacuum centrifugal degassing machine to the casting liquid inlet of the GY-TBA1012 coating machine via a transfer mechanism.

[0029] The online quality inspection unit includes a substrate CV-H500 visual inspection device, a finished film CV-H500 visual inspection device, and an L20H-D laser marking machine. The substrate inspection device is installed at the substrate inlet of the GY-TBA1012 coating machine, and the finished film inspection device and the laser marking machine are installed sequentially at the discharge end of the GY-TBA1012 coating machine.

[0030] The packaging unit is used to package the finished film.

[0031] Furthermore, the automatic metering and feeding device includes a solid raw material metering hopper, a liquid raw material metering tank, and a feeding device. The outlets of the solid raw material metering hopper and the liquid raw material metering tank are respectively connected to the reaction vessel through the corresponding feeding devices. Both the metering hopper and the metering tank are equipped with TSC200KG weighing sensors.

[0032] Furthermore, the reactor is a jacketed reactor, wherein the jacket is connected to a heating medium source via a pipeline.

[0033] Furthermore, the monitoring devices installed on the reactor body include a CP1W-TS101 temperature sensor, a DPSN1-B-10020 pressure sensor, an EE-SPX613 level sensor, and a DYJN-104 torque sensor.

[0034] Furthermore, the filtration device is at least a two-stage filtration device. The inlet of the first-stage filtration device is used to receive the material output from the outlet of the reactor. The two-stage filtration devices are connected in series. The outlet of the second-stage filtration device is connected to the inlet of the AD-10LA vacuum centrifugal degassing machine through an automatic transfer device. The AD-10LA vacuum centrifugal degassing machine is equipped with a vacuum centrifugal degassing machine ISE30A-01-NL pressure sensor.

[0035] Furthermore, the filtration accuracy of the primary filtration device is at least 5 μm, and the filtration accuracy of the secondary filtration device is at least 1 μm. Both filtration devices include a filter chamber and a removable filter membrane.

[0036] In this embodiment, solid and liquid raw materials are added to a jacketed reactor using an automatic metering and injection method. The jacket can be circulated with a heating medium (such as hot water or steam) to achieve heating. The reactor is equipped with a stirring device, and the stirring speed can be adjusted from 1 rpm to 2000 rpm. A CP1W-TS101 temperature sensor, a DPSN1-B-10020 pressure sensor, and an EE-SPX613 level sensor are installed on the reactor body to monitor the temperature, pressure, and level inside the reactor in real time. During stirring, the torque of the stirring shaft is monitored by a DYJN-104 torque sensor to indirectly determine the mixing uniformity of the materials.

[0037] In this embodiment, the automatic metering and feeding of solid raw materials is composed of a TSC200KG weighing sensor, a feeder, and a Siemens S7-1500 PLC. The feeding device of the aforementioned "solid raw material metering hopper" is the feeder. The TSC200KG weighing sensor is electrically connected to the Siemens S7-1500 PLC, and the Siemens S7-1500 PLC is electrically connected to the feeder. The TSC200KG weighing sensor acquires the total weight of the metering hopper at intervals. The Siemens S7-1500 PLC calculates the actual feeding flow rate based on the rate of weight change. After comparing it with the set value, it adjusts the speed of the V90 servo motor of the feeder through a PID algorithm to achieve closed-loop flow control. The aforementioned automatic metering and feeding technology for solid raw materials is a conventional prior art in this field. In this embodiment, the automatic metering and injection of liquid raw materials consists of a flow meter, a metering pump, and a Siemens S7-1500 PLC. The feeding device of the aforementioned "liquid raw material metering hopper" is the metering pump. The Siemens S7-1500 PLC collects the flow meter signal in real time and adjusts the stroke frequency of the metering pump through a PID algorithm. The aforementioned automatic metering and injection technology for liquid raw materials is a conventional existing technology in this field.

[0038] In this embodiment, the jacket is connected to the heating medium source (hot water tank / steam generator) via pipelines. A JLZDLP electric regulating valve and an LWGY-N flow sensor are installed on the pipelines. A CP1W-TS101 temperature sensor is embedded in the reactor body. The CP1W-TS101 temperature sensor is used to collect the reactor temperature in real time. A Siemens S7-1500 PLC control system is used to preset the target temperature. The CP1W-TS101 temperature sensor transmits the real-time temperature to the Siemens S7-1500 PLC. When the measured temperature is lower than the target value, the Siemens S7-1500 PLC controls the JLZDLP electric regulating valve to increase its opening, increasing the hot water / steam supply. When the temperature is higher than the target value, the opening is reduced. Temperature stabilization is achieved through closed-loop feedback. The above-described automatic control method for the jacket and heating medium source is conventional prior art in this field.

[0039] In this embodiment, the stirring device of the reactor is driven by a V90 servo motor, equipped with a reducer and a V20 frequency converter to achieve a speed adjustment range covering 1~2000 rpm. An E6B2-CWZ5B encoder is installed on the motor shaft to provide real-time feedback on the actual speed. The control system receives the speed setting command and outputs AC power of the corresponding frequency to drive the motor through the V20 frequency converter. The adjustment of the stirring parameters of the above-mentioned stirring device is conventional prior art in this field.

[0040] In this embodiment, the DPSN1-B-10020 pressure sensor, EE-SPX613 level sensor, and DYJN-104 torque sensor are selected for the reactor. Each sensor is connected to an S7-1500 PLC controller for real-time monitoring of parameters within the reactor. The DYJN-104 torque sensor is installed between the stirring shaft and the motor to collect the stirring resistance torque in real time. The Siemens S7-1500 PLC continuously collects torque data, which is compared with preset parameters for uniform material mixing to monitor the mixing status. The monitoring of the internal state of the reactor and the monitoring of the uniformity of material mixing described above are conventional existing technologies in the field.

[0041] In this embodiment, the "mechanical transfer structure" involved in the transfer of the casting liquid output from the reactor body to the casting liquid refining unit can be a robotic arm, a robotic hand, or other intelligent KR30 robot. Such equipment is widely used in automated and intelligent industries, and this application does not limit it, as long as it can realize the function of transferring the product output from each process to the next process.

[0042] Similarly, the casting solution, after being filtered by the primary and secondary filtration devices, enters the degassing stage via an automatic transfer mechanism, where it is defoamed using an AD-10LA vacuum centrifugal degassing machine. This automatic transfer can also be achieved using the aforementioned robotic arm, robotic gripper, or other intelligent robots. Of course, depending on the specific transfer steps involved, the robotic arm, robotic gripper, or other intelligent robot used may be a pneumatic gripper to directly pick up the barrelled material, or a vacuum suction cup, etc.

[0043] In this embodiment, the AD-10LA vacuum centrifugal degasser is equipped with a vacuum centrifugal degasser ISE30A-01-NL pressure sensor. The AD-10LA vacuum centrifugal degasser is a closed cavity, which is connected to the cavity via a vacuum pump. A JLZDLP electric regulating valve is installed on the pipeline to control the vacuum adjustment rate. A centrifugal drive mechanism is installed outside the vacuum cavity to rotate the vacuum cavity and adjust the centrifugal force. Specifically, the degassing process achieves bubble separation through the synergistic effect of vacuum environment and centrifugal force. The sealed chamber of the AD-10LA vacuum centrifugal degassing machine is evacuated to a low vacuum state. Due to the pressure difference, the gas inside the bubbles in the liquid expands, increasing the bubble volume and migrating towards the liquid surface. The chamber rotates at high speed with the centrifugal drive mechanism, and the liquid moves towards the edge of the chamber under the action of centrifugal force. Because the bubbles are less dense than the liquid, they are pushed towards the center region, accelerating their detachment from the liquid and bursting out. Once the bubbles are completely eliminated, the vacuum pressure inside the chamber tends to stabilize due to the lack of gas replenishment. The vacuum pressure change curve monitored by the DPSN1-B-10020 pressure sensor will change from a fluctuating state to a stable state, which serves as a sign that degassing is complete. The DPSN1-B-10020 pressure sensor is installed on the inner wall of the chamber to collect vacuum pressure in real time and is electrically connected to a Siemens S7-1500 PLC. During the degassing process, the Siemens S7-1500 PLC monitors the changes in the vacuum pressure inside the degassing machine through the DPSN1-B-10020 pressure sensor, compares it with the preset value, and determines that degassing is complete. Then, the Siemens S7-1500 PLC sends a signal to the vacuum generator and centrifugal drive mechanism, the vacuum pump stops working, and the centrifugal motor decelerates to a stop.

[0044] After the chamber pressure returns to normal, the Siemens S7-1500 PLC controls the gate to open. Once the gate is open, the material enters the membrane material preparation unit via automatic transfer. This automatic transfer can also be achieved using the aforementioned robotic arm, robotic gripper, or other intelligent robots.

[0045] One of the automated transfer mechanisms places the substrate at the front of the GY-TBA1012 coating machine. Specifically, depending on the type of GY-TBA1012 coating machine, it picks up single sheets or rolls of substrate from the substrate storage rack. The degassed casting solution is automatically transferred to the casting solution inlet of the GY-TBA1012 coating machine to begin preparing the film material. This automated transfer can also be achieved using the aforementioned robotic arm, robotic staff, or other intelligent robots. Simultaneously, the online quality inspection unit begins operation, including both substrate inspection and finished film inspection. After defect detection, defects are directly marked using a laser marking machine for convenient processing in subsequent processes.

[0046] After the membrane material is prepared, an automated transfer system is used to automatically remove the finished membrane from the GY-TBA1012 coating machine. Then, a 5030 extended packaging machine is used for empty box forming, product boxing, sealing, and final product output. During storage and transportation, AGV Q2-400D trolleys are used to transport finished materials for different storage processes.

[0047] Example 1

[0048] The present invention will be further illustrated by taking the preparation process of sulfonated polyetheretherketone membrane for flow batteries as an example:

[0049] 20 kg of sulfonated polyether ether ketone (PEEEK) granules and 100 kg of dimethylacetamide liquid were placed in raw material tanks A and B, respectively. Using an automatic metering and feeding system, 10 kg of PEEK granules and 40 kg of dimethylacetamide liquid were respectively placed in a stainless steel jacketed reactor. Water was used as the heating medium, the heating temperature was 40°C, the rotation speed was 400 rpm, and the dissolution time was 2 hours, yielding a PEEK casting solution with a solid content of 20%. The PEEK casting solution was then automatically transferred to the casting solution refining unit at a filtration flow rate of 5 kg / min. It first passed through a 5-micron filtration system, then further through a 1-micron filtration system, and was ready for use. The filtered casting solution then entered the degassing stage via an automatic transfer system, where it was degassed using an AD-10LA vacuum centrifuge. The defoaming machine was operated in defoaming mode, with a vacuum level set to 0.1 kPa, a rotation speed of 150 rpm, and a time of 20 minutes to obtain a ready-to-use sulfonated polyether ether ketone (PEEEK) casting solution. A KR30 robot automatically placed the polyethylene terephthalate (PET) substrate (100 micrometers thick, 50 cm wide) at the front of the GY-TBA1012 coating machine. The KR30 robot then transferred the defoamed casting solution to the membrane material preparation unit to begin membrane material preparation at a speed of 0.2 m / min, while the online quality inspection unit simultaneously started operating. After membrane material preparation was completed, the KR30 robot automatically removed the finished membrane from the GY-TBA1012 coating machine. Through the high integration of mechanical automation and intelligent control technology, the entire process from empty box forming, product boxing, sealing and packaging to finished product output was realized. The actual working time was 488 minutes, with a membrane preparation time of 300 minutes, producing a total of 60 meters of finished sulfonated PEEK membrane.

[0050] Comparative Example

[0051] Sulfonated polyetheretherketone (PEEEK) membranes were prepared using a traditional method. 20 kg of pre-prepared PEEEK granules and 100 kg of dimethylacetamide liquid were placed in raw material containers A and B, respectively. 10 kg of PEEEK granules and 40 kg of dimethylacetamide liquid were manually weighed and then manually added to a stainless steel jacketed reactor. Water was used as the heating medium, the temperature was 40°C, the rotation speed was 400 rpm, and the dissolution time was 2 hours, yielding a 20% solids content PEEEK casting solution. The PEEEK casting solution was then manually transferred to a casting solution refining unit with a filtration flow rate of 5 kg / min. It first passed through a 5-micron filtration system and then further through a 1-micron filtration system before use. The casting solution was manually transferred to the degassing stage, where an AD-10LA vacuum centrifugal degassing machine was used to remove bubbles at a vacuum level of 0.1 kPa, a rotation speed of 150 rpm, and a time of 20 minutes, yielding a ready-to-use sulfonated polyether ether ketone (PEEK) casting solution. A polyethylene terephthalate (PET) substrate, 100 micrometers thick and 50 centimeters wide, was manually placed at the front of a GY-TBA1012 coating machine. The degassed casting solution was then manually transferred to the membrane material preparation unit to begin membrane material preparation at a speed of 0.2 m / min. Visual quality inspection of the membrane material was performed manually throughout the entire process. After membrane material preparation, the finished membrane was manually removed from the GY-TBA1012 coating machine, and the product was boxed, sealed, and shipped. The actual working time was 1045 minutes, with a membrane preparation time of 300 minutes and a membrane preparation speed of 0.2 m / min, producing a total of 60 meters of finished sulfonated PEEK membrane.

[0052] In summary, as shown in the comparative examples and embodiments, it is evident that preparing the same number of sulfonated polyether ether ketone membranes using traditional methods requires 1045 minutes, while the intelligent membrane material preparation device designed in this invention can theoretically complete this task in only 488 minutes, improving the preparation efficiency by 53.3%. Furthermore, the intelligent membrane material preparation device designed in this invention significantly reduces the degree of human intervention, improving product consistency from the design stage.

[0053] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and are not intended to limit it. Although the utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this utility model.

Claims

1. An intelligent membrane material preparation device, characterized in that, It includes a raw material dissolution unit, a casting solution refining unit, a membrane material preparation unit, an online quality inspection unit, and a packaging unit. These units are connected sequentially via pipelines or mechanical conveying structures. The raw material dissolving unit includes an automatic metering and injection device and a reaction vessel. The outlet of the automatic metering and injection device is connected to the inlet of the reaction vessel. A stirring device is installed inside the reaction vessel, and a monitoring device is installed on the reaction vessel body. The casting solution refining unit includes a filtration device and a vacuum centrifugal degassing machine. The inlet of the filtration device receives the material from the outlet of the reactor through a transfer mechanism, and the outlet of the filtration device is connected to the vacuum centrifugal degassing machine. The membrane material preparation unit includes a coating machine, which transfers the material output from the vacuum centrifugal degassing machine to the casting liquid inlet of the coating machine via a transfer mechanism. The online quality inspection unit includes a substrate inspection device, a finished film inspection device, and a laser marking machine. The substrate inspection device is installed at the substrate inlet of the coating machine, and the finished film inspection device and the laser marking machine are installed sequentially at the discharge end of the coating machine. The packaging unit is used to package the finished film.

2. The intelligent membrane material preparation device according to claim 1, characterized in that, The automatic metering and feeding device includes a solid raw material metering hopper, a liquid raw material metering tank, and a feeding device. The outlets of the solid raw material metering hopper and the liquid raw material metering tank are respectively connected to the reaction vessel through the corresponding feeding devices. Both the metering hopper and the metering tank are equipped with weight sensors.

3. The intelligent membrane material preparation device according to claim 1, characterized in that, The reactor is a jacketed reactor, wherein the jacket is connected to a heating medium source via pipeline.

4. The intelligent membrane material preparation device according to claim 1, characterized in that, The monitoring devices installed on the reactor include a temperature sensor, a pressure sensor, a liquid level sensor, and a torque sensor.

5. The intelligent membrane material preparation device according to claim 1, characterized in that, The filtration device is a two-stage filtration device. The inlet of the first-stage filtration device is used to receive the material output from the outlet of the reactor. The two-stage filtration devices are connected in series. The outlet of the second-stage filtration device is connected to the inlet of the vacuum centrifugal degassing machine through an automatic transfer device. The vacuum centrifugal degassing machine is equipped with a DPSN1-B-10020 pressure sensor.

6. The intelligent membrane material preparation device according to claim 5, characterized in that, The primary filtration device has a filtration accuracy of at least 5μm, and the secondary filtration device has a filtration accuracy of at least 1μm. Both filtration devices include a filtration chamber and a removable filter membrane.

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