Secondary Battery Stacking Equipment Separator Alignment
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Solution Overview
Problem
Current secondary battery manufacturing processes face challenges such as reduced productivity, equipment size increase, separator misalignment, foreign substance contamination, and misalignment-induced product defects due to complex and inefficient electrode plate stacking mechanisms.
Innovation Solution
The implementation of a secondary battery manufacturing equipment with symmetrical electrode plate loading units, horizontal reciprocating stacking and separator supply units, and real-time alignment monitoring to ensure precise and efficient stacking of electrode plates with a separator in an intersecting manner, preventing misalignment and foreign substance inclusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the separator is linearly moved by a transfer rail and moved downward, then the separator can be positioned between electrode plates, but the separator may not be in close contact with the lateral side of the electrode plate, causing separator damage
Solution Approach 1:
The separator moving unit is changed from a linear transfer rail to a robotic manipulator that can dynamically adjust its movement path and positioning. This allows the separator to be precisely placed and maintained in close contact with the electrode plate lateral sides throughout the stacking process, preventing separator damage while ensuring accurate alignment.
2Manufacturing precision
If the second electrode plate is sequentially stacked on the first electrode plate by one electrode plate insertion unit, then the separator can be interposed between electrode plates, but the time required to manufacture one secondary battery increases, lowering productivity
Solution Approach 1:
Multiple electrode plate insertion units are combined into a single stacking device. These units operate simultaneously to stack multiple electrode plates and separators in parallel, maintaining precise alignment while significantly reducing the time required per battery and improving overall productivity.
Solution Approach 2:
The stacking device enables continuous stacking operations where multiple electrode plates and separators are processed simultaneously without interruption. This continuous action eliminates the sequential bottleneck, allowing the system to maintain high precision alignment while operating at maximum throughput.
3Productivity
If the first electrode plate and second electrode plate are supplied by different mechanisms, then the stacking process can be performed, but the electrode plates may not be normally aligned, causing misalignment defects
Solution Approach 1:
A single robotic manipulator is designed to perform multiple functions: it supplies both the first electrode plate and the second electrode plate, and also handles separator placement. This universal device ensures consistent alignment across all stacking operations by using the same positioning system for all components, eliminating misalignment defects.
4Ease of manufacture
If the electrode plate aligning unit and electrode inserting unit are disposed at different positions in vertical direction, then the stacking process can be performed, but the electrode plate may not be stably supplied or moved to stacking position
Solution Approach 1:
The stacking device uses an asymmetric vertical arrangement where the robotic manipulator operates from a centralized position to supply electrode plates at different heights. This asymmetric design allows stable supply by using gravity-assisted positioning and controlled descent mechanisms, ensuring each electrode plate is reliably placed at its target position despite the vertical displacement.
Data Source
AI summary
A secondary battery manufacturing equipment comprises: a main body unit; a pair of electrode plate loading units, disposed in the main body unit to face each other, for supplying electrode plates of different polarities; an electrode plate transfer unit for transferring the electrode plates of different polarities, supplied from the pair of electrode plate loading units, to a set stacking position in an intersecting manner; a stacking unit installed in the main body unit to be disposed at the stacking position for horizontally reciprocating within a first distance range which is set as the electrode plates are transferred in an intersecting manner; a separator supply unit installed in the main body so as to be disposed above the stacking unit for horizontally reciprocating within a second distance range which is set such that a separator is interposed between the electrode plates that are transferred in an intersecting manner.