Battery Cell Winding Line Without Daughter Coil Rewinding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The production process of cylindrical electrochemical cells, such as those used in electric vehicles, is inefficient and costly due to the need for unwinding mother coils, cutting strips, rewinding daughter coils, and manual feeding of strips to a winding device, which limits production capacity and poses safety risks.
Innovation Solution
A method and apparatus where electrode and separator sheets are unwound from mother coils and directly formed into multi-layer strips on a conveyor, which are then fed to automatic winding devices, eliminating the need for daughter coils and reducing manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mother coils are unwound, cut into strips, and rewound into daughter coils for assembly, then the electrochemical cell can be produced with standard sizes and proper layer arrangement, but the production process becomes complex and time-consuming with considerable temporary storage space required
Solution Approach 1:
The patent divides the continuous electrode and separator sheets into discrete strips of predetermined width using cutting devices. These strips are then arranged in a specific sequence (electrode, separator, electrode, separator) and fed simultaneously to the winding device, eliminating the need for unwinding and rewinding operations while maintaining precise layer arrangement.
Solution Approach 2:
The electrode and separator sheets are cut into strips and arranged in the correct sequence before being fed to the winding device. This preliminary preparation of strips in the proper arrangement eliminates the need for complex unwinding and rewinding operations, directly resolving the contradiction between manufacturing precision and process complexity.
2Device complexity
If strips are fed manually to the winding device from daughter coils, then the assembly can be completed with simple equipment, but the production capacity is limited and operator safety is at risk
Solution Approach 1:
The patent combines multiple strip feeding operations into a single automated process. Multiple strips (electrode and separator alternately) are fed simultaneously to the winding device in a coordinated manner, eliminating the need for sequential manual feeding and significantly increasing production capacity while reducing operator intervention.
Solution Approach 2:
The patent replaces manual mechanical feeding operations with an automated conveying system. The strips are transported and positioned by automated devices rather than being fed by hand, eliminating safety risks associated with manual intervention near rotating components while maintaining equipment simplicity.
3Ease of manufacture
If multiple coils are retained in the production plant for unwinding and rewinding operations, then the production process can be completed in stages, but considerable temporary storage space is required
Solution Approach 1:
The patent extracts and eliminates the intermediate daughter coil storage step from the production process. By cutting electrode and separator sheets into strips directly and arranging them in sequence before feeding to the winding device, the process removes the need for temporary storage of multiple coils, significantly reducing the area required for coil storage while maintaining staged production capability.
4Reliability
If operator attention is required to feed strips by hand to prevent injuries, then safety can be monitored in real-time, but the production process becomes a bottleneck
Solution Approach 1:
The patent replaces manual strip feeding operations with automated conveying and positioning devices. The automated system feeds multiple strips simultaneously to the winding device without requiring operator intervention near rotating components, eliminating the safety monitoring bottleneck while maintaining real-time safety through automated control systems.
Data Source
AI summary
A method for forming electrochemical cells of electrical batteries. The method comprises preparing a coil comprising a winding of a first separator sheet, a coil comprising a winding of a first electrode sheet, a coil comprising a winding of a second separator sheet and a coil comprising a winding of a second electrode sheet. The sheets are fed towards a movable conveyor by unwinding them from respective coils. A plurality of multi-layer strips is formed, each one comprising a first layer of said first separator sheet, a second layer of said first electrode sheet overlapped to said first layer, a third layer of said second separator sheet overlapped to said second layer and a fourth layer of said second electrode sheet overlapped to said third layer. Each multi-layer strip is fed to a respective winding device by said conveyor and each multi-layer strip is wound onto the respective winding device.