Battery Sheet Conveyor Roller with Magnetic Drive Assist
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Solution Overview
Problem
In the battery manufacturing process, the limited arrangement of rollers and the need for a small winding angle of the material around the rollers can result in insufficient static friction force, causing the rollers to stop rotating and leading to material damage or staining due to rubbing against the rollers.
Innovation Solution
A conveyor system with a roller, a shaft, a bearing, and a driver that rotates the shaft in the same direction as the material conveyance, using a magnetic coupling to transmit driving force and assist the roller's rotation, ensuring it aligns with the material's conveyance speed even when static friction is low.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the winding angle of the material around the roller is kept small due to limited roller arrangement, then the battery manufacturing process can proceed with compact layout, but the static friction force becomes insufficient causing the roller to stop rotating and the material to be damaged or stained
Solution Approach 1:
A shaft is introduced as an intermediary component between the driver and the roller. The driver rotates the shaft, and the shaft in turn rotates the roller through magnetic coupling. This intermediary shaft allows the system to overcome the insufficient static friction force by providing an additional rotational drive mechanism, enabling the roller to rotate properly even when the material's static friction force is insufficient due to small winding angle
Solution Approach 2:
The patent replaces the traditional direct mechanical contact drive system with a magnetic coupling system. Instead of relying solely on static friction between the roller and material for rotation, the system uses magnetic fields to transmit rotational force from the shaft to the roller. This substitution eliminates the need for sufficient static friction force while maintaining effective power transmission
2Speed
If the roller rotation speed does not coincide with the material conveyance speed due to insufficient winding angle, then the roller cannot effectively drive the material, but increasing the winding angle is not possible due to limited roller arrangement
Solution Approach 1:
The system incorporates speed detection and control mechanisms that monitor the roller's rotation speed and adjust the driver's output accordingly. By detecting the actual rotation speed and comparing it with the desired conveyance speed, the system can dynamically adjust the driving force to achieve synchronized speeds, ensuring proper material conveyance despite spatial constraints
Solution Approach 2:
The patent introduces a dynamic control system that adjusts the roller's rotation characteristics in real-time. The driver and shaft system can dynamically modify rotation speed and torque to match the material conveyance requirements, transforming a static mechanical system into a dynamically adaptable one that compensates for limited winding angle
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
Prevents material damage and staining by ensuring the roller rotates in sync with the material's conveyance speed, maintaining product quality despite limited winding angles and low static friction forces.
Implementation Method 1
using a magnetic coupling to transmit driving force and assist the roller's rotation
Implementation Method 2
a bearing installed between the roller and the shaft
Data Source
AI summary
In a manufacturing process of a battery or a circuit board, or a printing process, there is a case where a long sheet material is conveyed from an unwinding unit to a winding unit. One object of the present disclosure is to provide a technique capable of preventing the long sheet material from being rubbed by a roller when the material is conveyed. The present disclosure relates to a conveyor adapted for a battery manufacturing process. The conveyor comprises a roller configured to convey a long sheet material, a shaft through the roller; a bearing installed between the roller and the shaft, and a driver configured to rotate the shaft in the same direction as a rotating direction of the roller conveying the long sheet material.