Battery Coil Winding With Moving Heads and Strip Tension Buffering
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Solution Overview
Problem
The advancement speed of the strip-shaped article in relation to the winding unit in a coil production line limits production capacity, especially when high precision in winding geometry is required, leading to production line slowdowns and potential manufacturing quality issues due to tension states on the strip.
Innovation Solution
The apparatus includes a feed unit to continuously feed the strip-shaped article and a winding unit with multiple winding heads that can move along a working path, allowing for continuous advancement of the strip without interruption. The apparatus also includes a storage device to manage strip length and tension, enabling efficient winding and cutting processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the strip-shaped article is fed at high speed to the winding unit, then productivity is improved, but manufacturing precision deteriorates due to tension states on the strip
Solution Approach 1:
The winding head is made movable along the feed direction of the strip-shaped article, allowing dynamic adjustment of the winding position. This enables the winding unit to move synchronously with the strip feed, maintaining optimal winding conditions at high speeds without creating harmful tension states, thus resolving the contradiction between productivity and manufacturing precision
Solution Approach 2:
A movable support structure acts as an intermediary between the strip feed unit and the winding head. This intermediary component absorbs and compensates for feed speed variations, allowing the winding head to maintain precise positioning relative to the strip while moving at high speeds, thereby preserving manufacturing precision while improving productivity
2Speed
If the advancement speed of the strip is increased, then operating speed is improved, but manufacturing quality deteriorates due to tension states on the strip
Solution Approach 1:
The winding head is designed to move dynamically along the feed direction at variable speeds that synchronize with the strip advancement speed. This dynamic configuration allows the system to operate at high speeds while maintaining constant tension conditions, preventing manufacturing quality deterioration and ensuring reliable coil production
Solution Approach 2:
The system dynamically changes the positional parameter of the winding head along the feed direction based on the strip advancement speed. By adjusting the winding head position in real-time, the system maintains optimal tension parameters even at high operating speeds, thereby preserving manufacturing quality while improving speed
3Productivity
If multiple winding heads are used to increase productivity, then production capacity is improved, but device complexity increases
Solution Approach 1:
Multiple winding heads are merged onto a single movable support structure that moves together as one unit. This combining approach allows multiple winding operations to be performed simultaneously while using a unified control and movement system, increasing productivity without proportionally increasing device complexity
Solution Approach 2:
The movable support structure serves multiple functions: it supports multiple winding heads, provides synchronized movement for all heads, and acts as a common reference frame for positioning. This multi-functionality allows the system to achieve high productivity with minimal additional complexity, as one structure performs several critical roles
Data Source
AI summary
An apparatus (100) for making a coil (B) comprises a feed unit (2) configured to feed at least one strip-shaped article (N) formed by a plurality of strips (N1, N2, N3, N4) and a winding unit (1). The winding unit includes a plurality of winding heads (10) and a movement device (3) of said winding heads (10) configured to displace said winding heads (10) along a working path (P). The apparatus further comprises a storage device (4) configured so as to store a variable amount of said at least one of said strips (N1, N2, N3, N4) and an actuating device of the storage device (4) which displaces said storage device (4) to vary the stored amount of strip.