Battery Electrode Coil Winding With Moving Heads for Precision
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Solution Overview
Problem
The production of coils in electrochemical cell manufacturing is limited by the feed rate of strip-shaped articles and the need for high precision, which results in slowed production lines and potential tension issues in the strips.
Innovation Solution
The apparatus and method involve moving both the strip-shaped article and the winding heads during the winding process, allowing for continuous feeding and winding without interruptions, and using multiple winding heads to manage tension and increase production speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the feed rate of the strip-shaped article is increased to improve production capacity, then productivity increases, but manufacturing precision deteriorates due to tension issues in the strips
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 system to accommodate higher feed rates while maintaining precise winding control, as the winding head can move to optimize the winding geometry and reduce strip tension during high-speed operation.
Solution Approach 2:
A movement device is introduced as an intermediary component between the feed unit and the winding head. This movement device controls the position of the winding head along the feed direction, acting as a mediator that decouples the feed rate from the winding speed, thereby enabling high productivity while maintaining manufacturing precision through independent control of these parameters.
2Loss of time
If the feed rate is increased to reduce production time, then loss of time decreases, but manufacturing precision deteriorates due to interrupted movement and tension generation
Solution Approach 1:
The system enables continuous feeding and winding of the strip-shaped article without interruptions. The movable winding head maintains continuous contact with the strip during winding, and the feed unit operates continuously, eliminating stop-start cycles that would generate tension and compromise precision. This continuous operation reduces production time while maintaining geometric precision.
Solution Approach 2:
The winding head's ability to move dynamically along the feed direction allows the system to maintain continuous operation at high speeds. The movement device coordinates the winding head's position with the strip feed rate, ensuring continuous winding action without interruptions that would cause tension and precision loss.
3Productivity
If multiple winding heads are used to increase production speed, then productivity increases, but device complexity increases
Solution Approach 1:
The winding function is segmented into multiple independent winding heads that can operate simultaneously or in sequence. Each winding head is a modular unit with its own gripping device and movement control, allowing the system to increase productivity by adding more winding heads without requiring complete redesign of the entire apparatus. The segmentation enables scalable complexity.
Solution Approach 2:
The movement device serves multiple functions: it controls the position of the winding head along the feed direction, coordinates the operation of multiple winding heads, and adjusts the winding geometry as needed. This multi-functionality reduces the need for separate control mechanisms for each winding head, thereby limiting the increase in device complexity despite increased productivity.
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) and a winding unit (1). The feed unit (2) comprises a movable portion (20) that includes an outlet section (22) through which said strip-shaped article (N) passes through. The winding unit includes a plurality of winding heads (10) and a movement device for moving (3) said winding heads (10) configured to displace said winding heads (10) along a working path (P). The winding heads (10) and said movable portion (20) are both movable.