Battery Cell Activation Tray Misalignment Detection
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Solution Overview
Problem
The existing methods for manufacturing lithium secondary batteries do not effectively detect misassembly or misalignment of the inner tray during the activation process, leading to potential damage to battery cells due to collisions.
Innovation Solution
A method involving the installation of distance measuring sensors or object detection sensors on the outer tray to detect misassembly or misalignment of the inner tray by measuring distances or monitoring spaces around the inner tray's surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If no detection system is installed, then the activation process can proceed without additional equipment, but misassembly or misalignment of the inner tray cannot be detected, leading to potential damage to battery cells
Solution Approach 1:
The patent replaces mechanical inspection methods with optical sensors (laser sensors or vision sensors) to detect misassembly or misalignment of the inner tray. The sensors optically measure the position of the inner tray relative to the outer tray, substituting complex mechanical measurement systems with non-contact optical detection, thereby improving reliability while maintaining relatively simple device complexity.
2Measurement precision
If distance measuring sensors are installed to detect misalignment, then detection precision is improved, but the device complexity and cost increase
Solution Approach 1:
The patent employs optical sensors (laser sensors or vision sensors) to measure the position and alignment of the inner tray, replacing mechanical measurement tools. These sensors provide high measurement precision for detecting misalignment without requiring complex mechanical measurement systems, thus improving measurement precision while keeping the added complexity manageable.
Solution Approach 2:
The patent introduces sensors as intermediary detection elements between the inner tray and the control system. The sensors act as mediators that convert physical misalignment into electrical signals for processing, enabling precise detection without direct mechanical contact or complex measurement mechanisms.
3Reliability
If manual inspection is used, then equipment complexity remains low, but detection reliability and efficiency are insufficient, leading to potential undetected misassembly
Solution Approach 1:
The patent implements an automated detection system where the sensors automatically detect misassembly or misalignment of the inner tray during the activation process, eliminating the need for manual inspection. The system self-monitors the tray position and provides real-time detection, improving both reliability and productivity by continuously monitoring without interrupting the production flow.
Solution Approach 2:
The patent establishes a feedback mechanism where sensor detection results are fed back to the control system, which can then take appropriate actions (such as stopping the process or alerting operators). This closed-loop feedback improves detection reliability and ensures that misalignment issues are promptly addressed, thereby maintaining high productivity by preventing defects rather than requiring rework.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method allows for reliable and efficient detection of misassembly or misalignment, preventing damage to battery cells and improving the quality and reliability of battery cell activation trays.
Implementation Method 1
measuring a distance to one side surface of the inner tray in a longitudinal direction at two or more places spaced apart from each other
Data Source
AI summary
A method of detecting an occurrence of misassembled or misalignment of an inner tray during operation of a battery cell activation tray including an outer tray and the inner tray, the method includes installing a distance measuring sensor or an object detection sensor on the outer tray, and measuring a distance to one side surface of the inner tray in a longitudinal direction with the distance measuring sensor at two or more places spaced apart from each to compare the measured distance to a distance to a reference plane where the one side surface of the inner tray in the longitudinal direction is located in a normal state or determining that the misassembly of the inner tray or the misalignment of the inner tray during operation occurs depending on whether the inner tray is detected by the object detection sensor, respectively. A battery cell activation tray is also provided.