Coating Roll Roundness Measurement at Full Battery Line Speed
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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, only measures the outer periphery, and is prone to human error, making it difficult to accurately assess the roundness and coaxiality of the coating roll at actual line operating speeds.
Innovation Solution
A non-contact roundness measuring device using displacement sensors, installed on a support member along the length of the coating roll, measures roundness and coaxiality by detecting the outer diameter at multiple points, utilizing a linear movement mechanism and zero point adjustment to minimize errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a physical contact method through a dial gauge is used to measure roundness, then measurement can be performed, but the equipment line must be stopped or measured at low speed (2 m/min or less)
Solution Approach 1:
The patent replaces the mechanical contact measurement system (dial gauge with physical contact) with a non-contact measurement system using displacement sensors. This substitution eliminates the need for mechanical contact between the measurement tool and the coating roll, enabling measurement at actual line operating speeds without stopping or slowing down the equipment.
Solution Approach 2:
The patent introduces displacement sensors as an intermediary measurement tool that can detect the roundness of the coating roll without direct physical contact. These sensors act as a mediator between the measurement objective and the moving coating roll, capturing dimensional data through non-contact methods such as optical or electromagnetic fields.
2Measurement precision
If a physical contact method through a dial gauge is used, then roundness can be measured, but only the outer periphery is measured and important actual coating portions cannot be measured
Solution Approach 1:
The patent divides the measurement function into multiple displacement sensors positioned at different locations (including both outer periphery and inner coating areas). This segmentation allows simultaneous measurement of multiple zones on the coating roll, providing comprehensive data coverage that includes the previously inaccessible actual coating portions.
Solution Approach 2:
The patent extends measurement from a single-point contact method to a multi-point distributed measurement system. By positioning displacement sensors at various radial and axial positions, the system captures roundness data across multiple dimensions and spatial locations, including inner areas that are critical for coating quality but inaccessible to conventional dial gauges.
3Measurement precision
If a dial gauge is used for measurement, then roundness can be evaluated, but measurement errors occur due to skill level of the measuring person
Solution Approach 1:
The patent implements an automated measurement system where displacement sensors automatically capture and transmit roundness data without human intervention in the measurement process. The system self-records positional and dimensional data, eliminating the variability introduced by different measuring persons' skills and ensuring consistent, reliable measurements.
Solution Approach 2:
The patent incorporates automated data acquisition and processing where displacement sensor readings are directly captured and analyzed by a control system. This feedback mechanism eliminates human interpretation errors and ensures that measurement results are based on objective, quantifiable data rather than subjective assessment.
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 and coaxiality at actual line speeds, reducing human error and allowing for accurate assessment of the coating roll's quality, predicting potential abnormalities, and improving coating quality through real-time data correlation.
Implementation Method 1
a displacement sensor spaced apart from the coating roll and configured to measure the roundness of the coating roll in a non-contact manner
Data Source
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AI summary
Disclosed herein is a lamination apparatus for manufacturing an electrode cell assembly by laminating an electrode and a separator which are released from an electrode roll and a separator roll, which includes a lamination part in which the electrode cell assembly is laminated, an inspection part configured to measure a thickness of the manufactured electrode cell assembly and detect a defective electrode cell assembly, a discharging part configured to separate and discharge the defective electrode cell assembly from a normal electrode cell assembly, and a controller configured to calculate a point of time when the defective electrode cell assembly reaches the discharge part and control to separate and discharge the defective electrode cell assembly when the defective electrode cell assembly reaches the discharge part. In addition, the present invention relates to a method for discharging a defective electrode cell assembly of the lamination device.