In-Place Calender Roller Dent Inspection and Surface Repair
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Solution Overview
Problem
Existing methods for identifying and repairing imperfections on calender rollers require removing the rollers from the calender roll system, which is time-consuming and inefficient, especially when dealing with hard materials like electrode active materials that cause surface damage.
Innovation Solution
A method for mapping and repairing calender roller surfaces in-place, involving surface profiling, identifying dent areas, and depositing materials like metals or alloys directly on the roller while it remains installed, followed by polishing to match the surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If previous methods are used to identify and repair imperfections on calender rollers, then the imperfections can be detected and repaired, but the calender rollers must be removed from the system which is time-consuming
Solution Approach 1:
The calender roller system performs its own inspection and repair functions while remaining in place. The roller rotates on its own axis during the inspection process, and the deposition apparatus applies material directly to the roller surface without requiring external removal or handling of the roller.
Solution Approach 2:
The inspection and repair functions are extracted as separate operational steps that can be performed while the roller remains installed. The surface profiling, dent identification, and material deposition are performed as distinct operations that do not require removing the roller from the calender system.
2Measurement precision
If calender rollers are removed from the system for inspection and repair, then thorough examination and repair can be performed, but productivity is reduced due to downtime
Solution Approach 1:
The inspection and repair operations are performed continuously while the calender roller remains in its operational position. The roller continues to rotate and can potentially continue its calendering function while being inspected, and repair operations are performed without interrupting the overall system operation.
Solution Approach 2:
Surface profiling and dent identification are performed as preliminary steps before material deposition. This allows for precise localization of imperfections and planning of repair operations, ensuring that repair material is applied only where needed while maintaining production continuity.
3Reliability
If material is deposited at dent areas to repair imperfections, then surface defects are eliminated, but additional processing steps are required
Solution Approach 1:
Material deposition is applied locally only to the identified dent areas rather than the entire roller surface. The deposition apparatus targets specific coordinates based on the surface profile data, applying repair material only where imperfections exist, thereby eliminating unnecessary processing steps.
Solution Approach 2:
The system uses feedback from the surface profiling and dent identification steps to guide the material deposition process. The deposition parameters and location are determined by the measured surface characteristics, creating a closed-loop repair process that optimizes the number of steps required.
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
Enables efficient and time-saving inspection and repair of calender rollers without disassembly, ensuring defect-free film production and improved performance of electrode films in energy storage devices.
Implementation Method 1
measuring a first circumferential surface profile of the calender roller
Implementation Method 2
the depositing the material comprises depositing electroplating a metal or an alloy at the dent area
Data Source
AI summary
Systems and methods for mapping and/or repairing the surface of calender roller while the calender roller is still installed in the calender roll system are described. The methods for mapping and repairing a surface of a calender roller may comprise providing a calender roll system comprising a calender roller, mapping a surface profile of the calender roller, identifying a dent area on the surface of the calender roller at least partially based on the surface profile, and depositing a material at the dent area. The systems for mapping and repairing the surface of the calender roller are also described.