Battery Electrode Winding Alignment Using Layer Conversion Matrices
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Solution Overview
Problem
The manufacturing process of batteries faces challenges in maintaining precise alignment of electrode plates and diaphragms during winding, leading to potential internal short-circuits and safety risks due to displacement errors caused by thickness changes in the wound object, which existing methods fail to accurately monitor and correct in real-time.
Innovation Solution
A battery winding method that includes photographing each winding layer, acquiring position data of key points, converting data using a preset conversion matrix to account for thickness changes, and determining displacement within a threshold, ensuring accurate alignment and preventing excessive displacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the membrane layer composite is wound on the winding shaft, then the battery is manufactured, but the thickness of the wound object increases causing displacement errors between electrode plates
Solution Approach 1:
The patent applies preliminary action by pre-calculating and pre-storing conversion matrices for different winding layers before the actual winding process. The conversion matrices are computed in advance based on the known thickness of the membrane layer composite, allowing real-time position correction without adding computational complexity during winding. This resolves the contradiction by preparing correction data beforehand, maintaining manufacturing precision while avoiding real-time complexity.
Solution Approach 2:
The patent changes the parameter representation of electrode plate positions by introducing conversion matrices that transform coordinates from the current winding layer to a reference layer. Instead of directly measuring and controlling positions in a changing thickness environment, the system transforms position parameters using pre-computed conversion matrices, thereby maintaining alignment precision despite thickness variations.
2Measurement precision
If position data is acquired from photographed pictures, then the electrode plate positions are monitored, but errors arise due to thickness changes of the wound object
Solution Approach 1:
The patent introduces conversion matrices as an intermediary between the photographed position data and the actual electrode plate positions. The conversion matrices serve as a mediator that compensates for the harmful effect of thickness changes by transforming the measured positions into accurate reference positions. This intermediary mechanism eliminates measurement errors without requiring direct physical measurement corrections.
Solution Approach 2:
The patent creates a virtual reference copy of the electrode plate positions by converting current layer positions using pre-stored conversion matrices. Instead of directly using the photographed positions which are affected by thickness changes, the system generates a corrected copy of the positions through matrix transformation, thereby eliminating the harmful influence of thickness variations on measurement accuracy.
3Reliability
If real-time monitoring is implemented during winding, then displacement errors are detected, but the manufacturing efficiency is reduced
Solution Approach 1:
The patent applies preliminary action by pre-calculating all conversion matrices before the winding process begins. During real-time monitoring, the system only needs to perform simple matrix multiplication operations rather than complex real-time calculations. This preliminary preparation maintains reliability through continuous monitoring while minimizing the computational burden during winding, thereby preserving manufacturing efficiency.
4Manufacturing precision
If conversion matrices are used to correct position data, then manufacturing precision is enhanced, but the system complexity increases
Solution Approach 1:
The patent resolves the complexity issue by performing all matrix calculations in advance and storing the results. During the winding process, the system only retrieves and applies pre-computed conversion matrices through simple multiplication operations. This preliminary action transfers the computational complexity from the real-time winding process to an offline preparation stage, maintaining manufacturing precision while keeping the actual winding system simple and efficient.
Data Source
AI summary
Provided are a battery winding method, a battery winding system, a battery and an electrical device. The battery winding method includes: winding; photographing a picture of a current winding layer; acquiring position data of a first point and of a second point according to the picture of the current winding layer, converting the position data of the first point to obtain the converted position data of a converted first point using a preset conversion matrix corresponding to the current winding layer based on the number of the current winding layers and calculating data of displacement between the first and second electrode plates based on the converted position data of the converted first point and the position data of the second point, and determining if the data of displacement is within a threshold value scope, if so, returning to wind a next winding layer, and if not, sending an alarm.