Continuous Tape Feeder Automation for Battery Pack Assembly
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Solution Overview
Problem
In battery pack manufacturing, manual tape replacement and connection methods are inefficient, leading to production losses and potential quality issues due to incorrect tape attachment, as operators must visually identify and replace tape rolls, causing interruptions and suboptimal connections.
Innovation Solution
A continuous tape feeder system that automatically determines tape replacement timing using load cells and vision cameras, fuses and cuts tapes to ensure seamless continuous feeding, incorporating a controller to manage the process and an alarming unit for timely operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual tape replacement and connection methods are used, then operators can visually identify and replace tape rolls, but this leads to production losses and potential quality issues due to interruptions and suboptimal connections
Solution Approach 1:
The system enables automatic tape replacement and connection without manual intervention. The controller automatically detects when tape replacement is needed and controls the fusing unit and cutting unit to perform the replacement, allowing the system to serve itself rather than requiring operator intervention for each tape change.
Solution Approach 2:
The patent replaces manual mechanical operations with an automated control system. The controller uses detection signals from load cells and vision cameras to automatically control the fusing unit and cutting unit, substituting human visual identification and manual tape handling with sensor-based detection and automated mechanical operations.
2Productivity
If automatic tape replacement is implemented, then productivity is improved, but device complexity increases due to additional components
Solution Approach 1:
The controller serves multiple functions: it receives detection signals from both the load cell and vision camera, determines when tape replacement is needed, and controls both the fusing unit and cutting unit. This multi-functionality consolidates control logic into a single device, managing system complexity while enabling automated operation.
Solution Approach 2:
The load cell and vision camera act as intermediaries between the physical tape state and the controller's decision-making process. These sensors convert physical conditions (tape load, label position) into detection signals that the controller can process, bridging the gap between physical operations and automated control without requiring direct human intervention.
3Device complexity
If visual identification by operators is used, then simple device structure is maintained, but measurement precision of tape replacement timing is insufficient
Solution Approach 1:
The patent replaces human visual identification with sensor-based detection systems. The load cell measures tape load changes and the vision camera detects label positions, converting subjective visual assessment into objective, precise measurements that trigger automated tape replacement at the optimal timing.
Solution Approach 2:
The system implements feedback through detection signals from the load cell and vision camera that continuously monitor tape status. This feedback loop allows the controller to make real-time decisions about when to initiate tape replacement, ensuring precise timing based on actual system state rather than operator estimation.
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 system enables continuous, efficient, and high-quality tape feeding to battery pack assembly units, reducing production losses and improving productivity by automating the tape replacement and connection process, ensuring consistent tape supply without manual intervention.
Implementation Method 1
a fusing unit configured to connect the first tape to the second tape through fusion to form a connection portion
Implementation Method 2
a first load cell portion configured to detect a load of the first tape wound around the first tape fixing roll
Implementation Method 3
a vision camera unit arranged adjacent to the label adsorbing unit and configured to detect feeding of the label
Implementation Method 4
a label adsorbing unit configured to adsorb a label attached to the first tape and the second tape
Data Source
AI summary
A continuous tape feeder includes a first tape fixing roll configured to feed a first tape, a second tape fixing roll configured to feed a second tape, a fuser adjacent to the first tape fixing roll, the fuser being configured to connect the first tape to the second tape through fusion to form a connection portion, a cutter between the fuser and the first tape fixing roll, the cutter being configured to cut a first tape portion between the connection portion and the first tape fixing roll, and a controller configured to determine a timing for operating the fuser and the cutter.