Multi-Packaging Battery Line Layout for Maintenance Downtime
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Solution Overview
Problem
The existing secondary battery manufacturing facilities face productivity degradation due to frequent stoppages required for component replacement and equipment supply in the tab-welding and packaging units, leading to interruptions in the manufacturing process.
Innovation Solution
Implementing a multi-packaging unit system with a transfer unit that allows continuous supply and discharge of electrode assemblies by using a Multi-Line manufacturing approach, where a temporary buffer and transfer unit manage the flow between tab-welding and packaging units, enabling seamless operation even when one unit is stopped.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If component replacement and equipment supply are performed in the tab-welding unit and packaging unit twice a day, then maintenance and equipment supply can be completed, but manufacturing productivity is seriously degraded due to mandatory stoppages
Solution Approach 1:
The manufacturing system is divided into multiple independent packaging units (first packaging unit and second packaging unit) that can operate separately. When one packaging unit stops for maintenance or equipment supply, the other unit can continue manufacturing, thus segmenting the production flow to maintain overall productivity while allowing individual units to be maintained.
Solution Approach 2:
A transfer unit is introduced as an intermediary component between the tab-welding unit and the packaging units. This transfer unit includes a buffer that can temporarily store electrode assemblies, acting as a mediator that decouples the production flow. When one packaging unit stops, the buffer provides a buffer stock that allows the tab-welding unit to continue operating without interruption.
2Ease of repair
If the tab-welding unit stops for component replacement, then welding maintenance can be performed, but the electrode supply unit and packaging unit must also stop, causing complete line interruption
Solution Approach 1:
The system uses multiple packaging units that operate independently. When the tab-welding unit stops for welding maintenance, one packaging unit can continue operating with electrode assemblies already in the buffer, while the other packaging unit can be prepared or maintained. This segmentation prevents complete line interruption.
Solution Approach 2:
The buffer in the transfer unit pre-stores electrode assemblies before they are needed. This preliminary storage allows the packaging units to continue operating for a period even when the tab-welding unit stops for maintenance, as the buffer provides a head start that decouples the maintenance timing from the production timing.
3Ease of manufacture
If the packaging unit stops for equipment replacement, then pouch and electrolyte supply can be updated, but electrode assembly packaging cannot be performed, forcing line stoppage
Solution Approach 1:
With multiple packaging units operating in parallel, when one packaging unit stops for equipment replacement (pouch and electrolyte supply), the other packaging unit can continue the packaging operation. This segmentation of packaging functions ensures that equipment replacement in one unit does not force a complete line stoppage.
Solution Approach 2:
The buffer in the transfer unit acts as an intermediary that decouples the packaging operation from the tab-welding operation. When a packaging unit stops for equipment replacement, the buffer provides temporary storage that allows the system to maintain flow, and the other packaging unit can continue using electrode assemblies from the buffer.
4Device complexity
If In-Line manufacturing is used with sequentially arranged units, then the manufacturing process is simple to implement, but any unit stoppage causes complete production interruption
Solution Approach 1:
The system transitions from a single sequential In-Line arrangement to a segmented multi-line configuration with parallel packaging units. Each packaging unit operates independently with its own connection to the tab-welding unit through the buffer, creating segmented production paths that can operate independently, thus maintaining simplicity while improving continuity.
Data Source
AI summary
The present disclosure relates to a secondary battery manufacturing system having a multi-packaging unit, in which multiple packaging units of a secondary battery manufacturing facility are provided and a transfer box on which an electrode assembly is accommodated is transferred to each packaging unit by a transfer unit, wherein the secondary battery manufacturing system includes: an electrode supply unit equipped with a plurality of stacking devices for supplying an electrode assembly in which a plurality of battery cells are stacked; a tab-welding unit; at least one packaging unit; at least one temporary buffer; and a transfer unit.