Conveyor Buffer Rollers for Uninterrupted Cell Material Supply
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing electrode assemblies require stopping production when the supply roll of cell material runs low, leading to decreased productivity due to the need for equipment shutdown and roll replacement.
Innovation Solution
A conveyor system that allows for the continuous operation by lengthening or shortening the conveying route of a belt-shaped cell material, using movement parts and securing means to manage the cell material supply, enabling seamless transition between old and new rolls without stopping the equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the supply roll is replaced when cell material is depleted, then the equipment can continue operation, but production must be stopped temporarily causing productivity decline
Solution Approach 1:
The buffer section stores a predetermined amount of cell material in advance before depletion occurs. When the supply roll is replaced, the buffer section continues to supply material to the cutting section, allowing the replacement operation to be performed without stopping production. This preliminary storage of material resolves the contradiction by preparing a reserve that bridges the gap during roll replacement.
Solution Approach 2:
The conveying system is divided into distinct sections: a supply section for loading new rolls, a buffer section for storing reserve material, and a cutting section for processing. This segmentation allows independent operation of each section, enabling roll replacement in the supply section while the buffer and cutting sections continue operating, thus maintaining productivity without downtime.
2Reliability
If the conveying route is shortened during buffer section operation, then material supply continuity is maintained, but the buffer section must be precisely controlled
Solution Approach 1:
The buffer section employs movable rollers that can dynamically change position between extended and retracted states. This dynamic adjustment allows the conveying route length to be varied, enabling the buffer to supply material continuously while accommodating the replacement of supply rolls. The dynamic structure provides flexibility to maintain material flow without requiring complex control systems.
Solution Approach 2:
The buffer section acts as an intermediary between the supply section and the cutting section. It receives material from the supply roll, stores it temporarily, and releases it to the cutting section at the appropriate rate. This intermediary function smooths out variations in material flow, ensuring continuous supply to the cutting section while simplifying the control requirements compared to direct coupling of supply and cutting operations.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
[Problem] To provide a conveyor and a conveying method that can improve productivity without stopping equipment even when the supply roll is replaced. [Solution] A conveyor comprising: buffer rollers (322A, 322B) capable of lengthening and shortening a conveying route by holding belt-shaped cell material (W) fed out from a supply roll (110) in a conveyable manner and changing position, the cell material (W) being a material for an electrode or a separator, and the cell material being wound around the supply roll; and a buffer section clamp (323) capable of securing the cell material (W), the buffer section clamp being provided upstream from the buffer rollers (322A, 322B) along the direction in which the cell material is conveyed (W). The buffer rollers (322A, 322B) change position so as to shorten the conveying route in a state in which the cell material (W) is secured by the buffer section clamp (323).