Battery Stacking Apparatus Synchronization for Crease-Free Separator Positioning
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Solution Overview
Problem
Existing battery manufacturing techniques, such as those described in Patent Literature 1, elongate the manufacturing time due to the need for bearers and presser plates to stop and convey separators and electrodes, leading to inefficiencies in the stacking process.
Innovation Solution
A stacking apparatus and method that employs a conveyor system with suction belts, image pickup cameras, and rotary conveyance units to precisely position and stack separators and electrodes at high speed, synchronizing their movement to prevent creases and enhance processing accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the bearer and presser plate stop to draw and hold separators, then the separators can be precisely positioned and stacked, but the manufacturing time is elongated
Solution Approach 1:
The separator is drawn and held by the bearer before the stacking operation begins. The presser plate is pre-positioned and the thermal bonding edges are prepared in advance. This preliminary preparation allows the actual stacking to proceed continuously without stopping, as all components are ready to be assembled in motion.
Solution Approach 2:
The bearer and presser plate move continuously through the stacking process without stopping. The separator drawing, positioning, and thermal bonding all occur during continuous motion. This eliminates idle time between operations while maintaining precise positioning through synchronized movement and control systems.
2Manufacturing precision
If the bearer and presser plate stop to convey the packaged positive electrode, then the packaging can be completed accurately, but the manufacturing efficiency is reduced
Solution Approach 1:
The system transitions from static stopping operations to dynamic continuous motion operations. The bearer and presser plate maintain synchronized movement throughout the packaging process, with all positioning and bonding operations occurring during motion. This dynamic approach maintains packaging accuracy while eliminating stoppages that reduce productivity.
Solution Approach 2:
The patent replaces the traditional mechanical stopping and starting system with a continuous motion system controlled by synchronized drive mechanisms. Positioning is achieved through precise motion control rather than stopping at predetermined locations, allowing continuous operation without sacrificing packaging accuracy.
3Strength
If thermal bonding is performed on stationary separators, then the bonding strength is maximized, but the overall process speed is reduced
Solution Approach 1:
The thermal bonding process occurs in periodic cycles during continuous motion. The heater elements are activated in sequence as the separators pass through the bonding zone, with each separator receiving the necessary thermal energy during brief contact periods. This periodic heating maintains bonding strength while allowing continuous throughput without stopping the conveyance system.
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
This approach significantly shortens the manufacturing time of batteries by enabling continuous, high-speed stacking of separators and electrodes without stoppages, improving precision and preventing creases during the process.
Implementation Method 1
a suction belt that draws and holds the positive electrode on a mounting surface
Implementation Method 2
The stacking drum has a suction area on an outer circumferential surface to draw and hold the separator
Implementation Method 3
an image pickup camera to detect a position of the positive electrode
Data Source
Figure 1
Figure 2
Figure 3(A)~3(B)
AI summary
The stacking apparatus of the present invention includes a separator conveyance unit to convey a separator of predetermined shape in a held state, an electrode conveyance unit to convey a positive electrode of predetermined shape, and a control unit to synchronize the conveying position and conveyance speed of the separator conveyance unit with those of the electrode conveyance unit so that the separator and positive electrode overlap each other at a predetermined position. The stacking apparatus conveys the separator and positive electrode and transfers the separator onto the electrode from a downstream side of the conveying direction while gradually removing the separator from the separator conveyance unit, thereby stacking the separator on the electrode.