Dry Electrode Film Trimming With Vision-Based Width Alignment
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Solution Overview
Problem
Conventional dry electrode manufacturing apparatuses struggle to control the width, position, and alignment of free-standing films laminated onto current collectors in real-time, leading to instability in the manufacturing process.
Innovation Solution
A dry electrode manufacturing apparatus equipped with trimming knives and suction portions, controlled by a vision system and controller, adjusts the width and position of free-standing films on current collectors in real-time, ensuring precise lamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional dry electrode manufacturing apparatus is used, then the basic lamination function is achieved, but the width, position, and alignment control of free-standing film is unstable
Solution Approach 1:
The patent implements a feedback control system where a vision device detects the actual width and position of the free-standing film, and this information is fed back to automatically adjust the trimming knives' positions. This closed-loop feedback mechanism ensures stable and precise width control, directly resolving the contradiction between manufacturing precision and process stability.
Solution Approach 2:
The patent replaces manual or purely mechanical width control methods with an automated system combining vision detection and computer-controlled trimming. This substitution of mechanical control with automated sensing and actuation systems enables precise and stable width, position, and alignment control throughout the manufacturing process.
2Manufacturing precision
If real-time control of free-standing film width and position is implemented, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent employs a multi-functional integrated control system where a single controller coordinates multiple trimming knives across different stations, manages vision device data, and synchronizes adjustments. This universal control approach consolidates multiple control functions into one system, reducing overall complexity while achieving precise position and alignment control.
Solution Approach 2:
The vision device creates optical copies (images) of the free-standing film to detect its width and position without physical contact. This non-contact copying method enables real-time measurement and control while avoiding the complexity of physical measurement mechanisms, simplifying the overall control system.
3Manufacturing precision
If trimming knives are used to adjust film width, then manufacturing precision is improved, but the complexity of the apparatus increases
Solution Approach 1:
The patent divides the trimming function into multiple segmented trimming knives positioned at different stations along the production line. Each trimming knife handles a specific section of the width adjustment, allowing precise control at different stages. This segmentation enables distributed precision control while managing the complexity of having multiple components through functional division.
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 apparatus improves the quality and stability of the dry electrode manufacturing process by precisely controlling the width, position, and alignment of free-standing films on current collectors.
Implementation Method 1
a first suction portion that is positioned adjacent to the first trimming knives and is configured to suction material separated from the first free standing film by the plurality of first trimming knives
Data Source
AI summary
A dry electrode manufacturing apparatus includes a plurality of rollers that laminate fine powder onto a current collector by calendaring the fine powder into a free standing film. A plurality of trimming knives adjust a film width of the free standing film passing by at least one roller among the plurality of rollers. A vision portion photographs a surface of the current collector on which the free standing film is laminated. A controller controls positions of the trimming knives based on the film width of the free standing film laminated onto the surface of the current collector.