Coating Roll Roundness Measurement Using Non-Contact Sensor Arrays

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Solution Overview

Problem

Existing roundness measurement methods for coating rolls in battery manufacturing are limited by physical contact, which restricts measurement speed, accuracy, and the ability to measure the actual coating portion.

Innovation Solution

A non-contact roundness measuring device using displacement sensors installed on a support member extending along the length direction of the coating roll, allowing for simultaneous measurement of roundness and coaxiality at multiple points.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a physical contact method (dial gauge) is used to measure roundness, then measurement can be performed with simple equipment, but measurement speed decreases and the coating roll must be stopped

Engineering Contradiction:

Improvemeasurement speedVSAvoidroundness measurement accuracy

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The patent replaces the mechanical contact measurement system (dial gauge with gears) with a non-contact optical measurement system (laser displacement sensor). This substitution eliminates mechanical contact, allowing the coating roll to rotate at actual line speeds while being measured, thereby resolving the contradiction between measurement speed and measurement capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a laser displacement sensor as an intermediary measurement tool that can capture roundness data without physically touching the coating roll. This intermediary device enables continuous measurement during operation, solving the problem of stopped equipment required by traditional contact methods.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If a physical contact method is used, then equipment complexity is low, but measurement location is limited to outer periphery only

Engineering Contradiction:

Improvemeasurement location coverageVSAvoidmeasurement system complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The laser displacement sensor system replaces the limited-contact dial gauge method, enabling measurement at multiple locations including the actual coating portion (central area) rather than just the outer periphery. The optical nature of the sensor allows it to measure across different radial positions without mechanical interference.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Measurement precision

If multiple displacement sensors are installed to measure at multiple points, then measurement comprehensiveness improves, but device complexity increases

Engineering Contradiction:

Improveroundness measurement accuracyVSAvoidsensor arrangement complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent divides the measurement task into multiple discrete displacement sensors positioned at different locations (e.g., both ends and center of the coating roll). Each sensor independently measures roundness at its specific location, and the results are integrated to provide comprehensive assessment. This segmentation enables multi-point measurement while maintaining system manageability.

Inventive Principle:

Principle #1Segmentation

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 real-time measurement of roundness at actual line operating speeds, reduces measurement errors, and allows for accurate assessment of both the outer periphery and actual coating portions of the coating roll.

Implementation Method 1

a displacement sensor (40) spaced apart from the coating roll (20) and configured to measure the roundness of the coating roll (20) in a non-contact manner

Methodology Applied

Scientific EffectDisplacement sensor detection:

Data Source

PatentUS12287191B2Measurement device and measurement method for measuring roundness of coating roll for manufacturing battery

Publication Date: 2025.04.29 LG ENERGY SOLUTION LTD

AI summary

Disclosed herein is a roundness measuring device and a roundness measuring method of a coating roll for battery manufacturing. The roundness measuring device of a coating roll that supports an electrode sheet when the electrode sheet is coated with an electrode slurry, the roundness measuring device comprising: a displacement sensor spaced apart from the coating roll and configured to measure roundness of the coating roll in a non-contact manner; and a support member on which the displacement sensor is installed and which extends in a length direction of the coating roll, wherein the displacement sensor is installed as a plurality of displacement sensors on the support member in the length direction of the coating roll.