Battery Sheet Tension Control to Prevent Electrode Skew
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Solution Overview
Problem
Existing secondary battery manufacturing processes face challenges in preventing skew failure of electrode plates and separators, which can lead to winding failures and uneven formation, potentially causing short circuits in batteries.
Innovation Solution
A secondary battery manufacturing apparatus and method that includes a roller system with sensors to measure sheet tension and a driver to control the roller's operation based on measured tension, adjusting the feeding amount and moving angle of the roller to maintain optimal tension and prevent skew failure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sheet is conveyed through the roller without tension control, then the manufacturing process is simple, but skew failure occurs leading to winding failures and uneven formation
Solution Approach 1:
The system employs a sensor to detect sheet tension during conveyance and feeds this information back to the driver, which automatically adjusts the roller's feeding amount and moving angle. This closed-loop feedback control maintains optimal tension without manual intervention, preventing skew failure while managing system complexity through automation.
Solution Approach 2:
The roller control system is designed to self-regulate tension by automatically adjusting its own operation parameters (feeding amount and moving angle) based on sensor feedback. The system serves itself by autonomously correcting tension deviations without requiring external control, thereby improving reliability while keeping the control mechanism streamlined.
2Manufacturing precision
If the roller operation is manually controlled, then the device complexity is low, but the manufacturing precision of sheet tension control is insufficient
Solution Approach 1:
The patent replaces manual mechanical control with an automated electromechanical system. The driver electronically controls the roller's feeding amount and moving angle based on sensor data, substituting human operation with an automated control mechanism that achieves higher precision tension control while managing complexity through integration.
Solution Approach 2:
The system dynamically changes operational parameters (feeding amount and moving angle of the roller) based on real-time tension measurements. By automatically adjusting these parameters to maintain optimal tension, the system achieves high manufacturing precision without requiring complex manual intervention, as the control logic handles parameter optimization autonomously.
3Measurement precision
If multiple sensors are used to measure tension at different positions, then the measurement precision is improved, but the device complexity increases
Solution Approach 1:
The tension measurement is divided into multiple segments by placing sensors at different positions along the sheet path. Each sensor measures tension at a specific location, and the driver integrates these segmented measurements to determine overall tension status and adjust roller operation accordingly. This segmentation improves measurement comprehensive precision while managing complexity through distributed sensing.
Solution Approach 2:
Multiple sensors serve the universal function of tension measurement across different positions, with each sensor contributing to the overall tension control objective. The driver processes inputs from all sensors to make unified control decisions, making the sensor system multi-functional in monitoring tension throughout the conveyance path while achieving high measurement precision without proportionally increasing control complexity.
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
The solution effectively minimizes skew failure of sheets during the manufacturing process, ensuring consistent and balanced formation of electrode plates and separators, thereby reducing the risk of short circuits and improving the overall quality of secondary batteries.
Implementation Method 1
a sensor measuring tension of the sheet
Data Source
AI summary
A secondary battery manufacturing apparatus includes at least one roller configured to convey a sheet, at least one sensor configured to measure a tension of the sheet, and a driver configured to control operation of the at least one roller, based on the tension measured by the at least one sensor.