Die Coater Lip And Shim Sensing for In-Line Assembly Accuracy
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Solution Overview
Problem
Existing die coater inspection methods struggle to precisely measure the position of lips and shims in die coaters, leading to assembly defects and inconsistent electrode quality, especially when the die coater is mounted on a production line without a separate inspection line.
Innovation Solution
A die coater inspection device equipped with a sensor module that moves in the thickness direction of the die coater, featuring a position detection sensor to detect the edge of the lip and a distance detection sensor to measure the height of the lip or shim, allowing for precise measurements and immediate inspections without a separate inspection line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a user directly contacts a micrometer to measure the height of lips and shims, then measurement can be performed, but measurement precision deteriorates due to difficulty in accessing narrow gaps and varying user techniques
Solution Approach 1:
The patent replaces manual mechanical micrometer measurement with an automated optical sensor system. The sensor module non-contactly measures the positions of lips and shims, eliminating the need for direct mechanical contact in narrow gaps. This substitution resolves the contradiction by providing both ease of operation (automated measurement) and high measurement precision (optical sensing capability).
Solution Approach 2:
The patent introduces a sensor module as an intermediary between the measurement system and the lips/shims. This intermediary component enables precise measurement by converting physical dimensions into electrical signals that can be processed automatically, thereby resolving the accessibility and precision contradiction.
2Measurement precision
If a separate inspection line is provided for die coater inspection, then measurement precision can be maintained, but productivity deteriorates due to additional inspection time and equipment
Solution Approach 1:
The patent merges the inspection function with the production line by integrating the sensor module directly into the die coater assembly process. This allows inspection to occur simultaneously with production operations, eliminating the need for a separate inspection line while maintaining measurement precision through automated sensing.
Solution Approach 2:
The sensor module serves multiple functions: it measures lip positions, shim positions, and gap dimensions all within the same inspection system. This multi-functionality enables comprehensive inspection without requiring additional dedicated equipment, thereby maintaining precision while improving productivity.
3Ease of manufacture
If the die coater is disassembled for internal cleaning, then manufacturing precision can be maintained through cleaning, but assembly precision deteriorates due to position deviation of lips and guides upon reassembly
Solution Approach 1:
The patent performs inspection before disassembly to establish baseline position data for lips and shims. This preliminary measurement allows for accurate reassembly by providing reference values against which post-reassembly positions can be compared, thereby preventing position deviation issues.
Solution Approach 2:
The inspection system provides feedback on the positions of lips and shims both before and after reassembly. This feedback mechanism enables verification of assembly accuracy and facilitates corrective adjustments if position deviations occur during the disassembly-reassembly cycle.
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
The solution enables automatic detection of lip and shim positions and heights, reducing measurement errors and allowing for immediate inspections during production, thereby ensuring consistent electrode quality and reducing assembly defects.
Implementation Method 1
a position detection sensor configured to detect a position of an edge of the lip by changing a transmitted signal from a first signal to a second signal
Implementation Method 2
a distance detection sensor configured to measure a height of the lip or the shim
Data Source
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AI summary
A die coater inspection device for inspecting a die coater including a first die, a second die, and a shim formed between the first die and the second die according to an embodiment of the present invention for achieving the above object includes: a sensor module moving in a thickness direction of the die coater and configured to inspect a lip or the shim of the die coater; a control part configured to control an operation of the sensor module; and a storage part in which reference data on the thickness of the lip or the shim is stored, wherein the sensor module includes: a position detection sensor configured to detect a position of the lip; and a distance detection sensor configured to measure a height of the lip or the shim, and the control part includes: a first encoder configured to recognize a coordinate value of the sensor module whenever the sensor module moves in the thickness direction of the die coater; a reception part configured to receive a signal transmitted by the position detection sensor; a determination part configured to determine the position of the lip or the shim according to the signal received by the reception part; and a calculation part configured to perform calculation based on the position of the lip or the shim and the coordinate value so as to derive a coordinate value of the lip or a coordinate value of the shim.