Die Coater Lip and Shim Inspection for On-Line Assembly Accuracy
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Solution Overview
Problem
Existing die coaters face challenges in precisely measuring the position of lips and shims to detect assembly defects, especially when mounted on a production line without a separate inspection line, leading to potential quality issues in electrode manufacturing.
Innovation Solution
A die coater inspection device is integrated onto one surface of the first die, featuring a rail for a sensor assembly to move along and inspect the lips and shims. This device includes position and distance detection sensors, enabling precise measurement of lip and shim positions and heights without direct user contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a die coater is disassembled and reassembled for internal cleaning, then the die and shim can be cleaned, but the positions of the lips and guide may deviate from original positions, causing quality variation
Solution Approach 1:
The patent replaces manual mechanical measurement and positioning with an automated optical inspection system. Sensors detect the positions of lips and guide, and a control unit automatically determines whether reassembly is needed, eliminating manual intervention that causes position deviation
Solution Approach 2:
The die coater is equipped with self-inspection capabilities through integrated sensors and control units that automatically monitor the positions of lips and guide, enabling the system to self-diagnose assembly defects without external inspection equipment
2Ease of operation
If manual measurement with micrometer is used to measure lip positions, then measurement can be performed, but measurement errors increase due to different users and the narrow gap makes direct contact difficult
Solution Approach 1:
The patent replaces manual mechanical micrometer measurement with an automated optical sensing system. Sensors automatically detect lip positions without physical contact, eliminating user-dependent variability and the difficulty of accessing narrow gaps
Solution Approach 2:
The patent introduces sensors as intermediary devices between the measurement system and the lips. These sensors can detect positions through the narrow gaps without requiring direct contact, serving as a mediator that overcomes the physical access limitation
3Measurement precision
If a separate inspection line is provided for die coater inspection, then thorough inspection can be performed, but production efficiency decreases due to additional inspection steps
Solution Approach 1:
The patent merges the inspection function with the die coater itself by integrating sensors and control units directly into the coating head. This combination eliminates the need for separate inspection lines while maintaining inspection accuracy
Solution Approach 2:
The die coater is designed with multi-functionality, serving both as a coating application device and as an inspection system. The integrated sensors and control unit enable the same equipment to perform both coating and quality verification functions
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 allows for accurate detection of assembly defects in die coaters, reducing measurement errors and enabling immediate inspections on the production line, thereby enhancing production efficiency and ensuring consistent electrode quality.
Implementation Method 1
a position detection sensor configured to detect the position of the lip
Implementation Method 2
a distance detection sensor configured to measure the height of the lip or the shim
Data Source
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AI summary
A 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 solving the above problem includes a rail formed to be fixed long on one surface of the first die in a longitudinal direction of the die coater, and at least one sensor assembly configured to move along the rail and inspect a lip or the shim of the die coater, wherein the sensor assembly includes a movable part moving along the rail in the longitudinal direction of the die coater, and a sensor module connected to the movable part, and configured to move in a thickness direction of the die coater and inspect the lip or the shim.