Coating Die Position Control for Roller Run-Out Compensation
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Solution Overview
Problem
The coating process for lithium-ion traction batteries often results in uneven slurry thickness due to equipment fluctuations, particularly circular run-out errors in the coating roller, which affects the electrochemical performance and reliability of the batteries.
Innovation Solution
A coating apparatus with a coating module, error acquisition module, and linkage module that adjusts the position of the coating die in real-time to maintain a constant distance between the coating roller and die, using a displacement transfer module driven by a piezoelectric ceramic and elastic members to compensate for circular run-out errors, ensuring even slurry thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the coating roller rotates to drive the substrate, then the coating process can be performed, but circular run-out error causes uneven coating thickness
Solution Approach 1:
The error acquisition module continuously monitors the circular run-out error of the coating roller during rotation and feeds this information to the linkage module, which then adjusts the coating die position in real-time to compensate for the detected deviations, maintaining uniform coating thickness despite roller imperfections
Solution Approach 2:
The patent replaces pure mechanical positioning with a hybrid system that uses piezoelectric ceramics to convert electrical signals from the error acquisition module into precise mechanical displacement of the coating die, enabling dynamic compensation that overcomes limitations of traditional mechanical adjustment systems
2Device complexity
If the distance between coating roller and coating die is fixed, then the structure is simple, but equipment fluctuation causes uneven coating thickness
Solution Approach 1:
The patent transforms the static, fixed distance structure into a dynamic system where the linkage module continuously adjusts the coating die position based on real-time feedback from the error acquisition module, allowing the system to adapt to roller fluctuations while maintaining coating precision
Solution Approach 2:
The linkage module acts as an intermediary between the error acquisition module and the coating die, translating detected run-out errors into compensatory position adjustments, thereby decoupling the simplicity of the fixed structure from the requirement for precision
3Manufacturing precision
If real-time adjustment of coating die position is implemented, then coating thickness uniformity is improved, but device complexity increases
Solution Approach 1:
The patent employs piezoelectric ceramics to replace complex mechanical transmission mechanisms, using direct electro-mechanical conversion to achieve precise coating die position adjustment with minimal mechanical components, thereby reducing overall system complexity while maintaining high precision
Solution Approach 2:
The system changes the control parameter from mechanical position setting to electrical voltage control of the piezoelectric ceramic, allowing precise adjustment of the coating die position through electrical signals that correspond directly to the measured run-out errors
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 solution ensures consistent and even slurry thickness on electrode plates, enhancing the electrochemical performance and reliability of lithium-ion traction batteries by mitigating the impact of equipment fluctuations during the coating process.
Implementation Method 1
the piezoelectric ceramic, deforming when receiving the voltage signal and configured to push the displacement transfer module to produce displacement
Implementation Method 2
an elastic member, fastened to the piezoelectric ceramic, where deformation of the piezoelectric ceramic pushes the elastic member to deform
Data Source
AI summary
Provided are a coating apparatus and a coating system, where the coating apparatus includes: a coating module, the coating module including a coating roller and a coating die, where the coating roller is configured to drive, when rotating, a substrate to move toward the coating die, and the coating die is configured to apply a coating onto the substrate; an error acquisition module having a predetermined distance to the coating roller and configured to acquire a circular run-out error of rotation of the coating roller and transmit the circular run-out error to a linkage module; and the linkage module configured to adjust position of the coating die in real time according to the circular run-out error transmitted to the linkage module, so as to keep a distance between the coating roller and the coating die unchanged.