Rechargeable Battery Tab Positioning for Precise Welding Alignment
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Solution Overview
Problem
Existing methods for manufacturing rechargeable batteries face challenges in aligning electrode tabs accurately, leading to defects during welding and varying manufacturing quality due to user skill dependence.
Innovation Solution
A method involving numerical value entry, calculation, and position-setting operations using a processor to align electrode tabs based on Equation 1, automating the process to ensure precise tab positioning regardless of user skill.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual methods are used to set electrode tab positions, then user flexibility is maintained, but manufacturing precision and alignment accuracy deteriorate due to skill dependence
Solution Approach 1:
The design system automatically calculates and determines optimal electrode tab positions based on input parameters (electrode plate dimensions, winding specifications, etc.), eliminating the need for manual intervention. The system serves itself by using built-in algorithms and equations to generate positioning data, ensuring consistent high precision without relying on user skill levels.
Solution Approach 2:
The patent replaces manual mechanical positioning methods with an automated computational system. Instead of relying on operators to physically measure and mark positions, the system uses numerical calculations based on Equation 1 and computer-aided design software to determine precise tab locations, substituting human mechanical operations with automated digital computation.
2Manufacturing precision
If automated calculation methods are implemented, then manufacturing precision improves, but device complexity increases due to additional computational operations
Solution Approach 1:
The system performs all necessary calculations and position determinations before the actual manufacturing process begins. By pre-calculating optimal tab positions using Equation 1 and storing these values in the design data, the system eliminates the need for complex real-time computations during manufacturing, reducing operational complexity while maintaining high precision.
Solution Approach 2:
The automated design system serves multiple functions: it calculates electrode plate dimensions, determines winding parameters, positions electrode tabs, and generates manufacturing instructions all within a single integrated platform. This multi-functionality consolidates what would otherwise require multiple separate tools and processes into one universal system.
3Reliability
If precise electrode tab alignment is achieved through automation, then welding defects are reduced, but manufacturing time increases due to calculation operations
Solution Approach 1:
The design system operates continuously and efficiently through automated calculations, eliminating interruptions and rework. By integrating the calculation process directly into the design workflow and using optimized algorithms, the system maintains continuous productive action rather than stopping for manual measurements and adjustments, ultimately reducing total manufacturing time despite the added computational step.
Solution Approach 2:
The system incorporates feedback mechanisms where calculation results are immediately validated and used to adjust subsequent design parameters. If calculated positions fall outside acceptable tolerances or create conflicts, the system automatically iterates to find optimal solutions, ensuring welding quality without requiring multiple manual review cycles that would extend processing time.
Data Source
AI summary
A method of designing a rechargeable battery includes a numerical value entering operation for entering detailed numerical values for a case, a separator, and an electrode plate, a calculation operation for deriving X and until an equation is satisfied, and a position-setting operation for setting the position of an electrode tab to be located on one side of the electrode plate.