Dry Electrode Roll Transfer With Vacuum Holding and Tension Control
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Solution Overview
Problem
The existing manufacturing systems for dry electrodes in secondary batteries face challenges in automating the replacement of roll cores, leading to reduced productivity and increased labor due to the low tensile strength of the dry electrodes, which complicates the manual process of cutting and reconnecting the electrodes.
Innovation Solution
A system comprising an automatic connection device with a tension control mechanism and a connection device that includes a fixed roller, swing roller, and holder plate, capable of vacuum adsorption, to automatically transfer the dry electrode from a working core to a standby core without manual intervention, ensuring continuous operation and maintaining tension control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual cutting and reconnection of dry electrodes is used, then the process can be completed with simple equipment, but productivity decreases and labor costs increase due to low tensile strength complications
Solution Approach 1:
The connection device is divided into multiple functional modules: a holder plate for gripping the electrode, a cutting blade for separation, and a tension control mechanism for maintaining electrode integrity. This segmentation allows each component to perform its specific function efficiently while keeping the overall system manageable in complexity
Solution Approach 2:
The holder plate acts as an intermediary component that grips the dry electrode during the cutting and reconnection process. This intermediary device provides controlled support to the low-tensile-strength electrode, enabling automated manipulation without direct manual handling
2Productivity
If automated connection device is implemented, then productivity increases and manual labor decreases, but the device complexity and initial investment increase
Solution Approach 1:
The tension control mechanism automatically adjusts and maintains appropriate tension on the electrode during the connection process without requiring manual intervention. The device performs self-regulation of critical parameters, reducing the need for operator skill and attention while maintaining high productivity
Solution Approach 2:
The holder plate pre-grips the electrode at the cutting position before the cutting blade acts, and the tension control mechanism pre-establishes proper tension. These preliminary actions prepare the electrode for automated handling, making the subsequent cutting and reconnection operations straightforward and reliable
3Reliability
If manual handling of dry electrodes is used, then equipment cost is lower, but material breakage risk increases due to low tensile strength
Solution Approach 1:
The holder plate serves as an intermediary that provides controlled gripping force on the electrode, distributing stress evenly and preventing localized damage. This intermediary device protects the low-tensile-strength electrode from breakage during automated manipulation
Solution Approach 2:
The tension control mechanism dynamically adjusts the tension parameter during the connection process to match the electrode's low tensile strength characteristics. By controlling tension within safe limits, the device prevents material breakage while enabling automated operation
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 solution enables automatic replacement of roll cores, reducing manual labor, improving the quality of connections, and preventing material breakage, thereby increasing productivity and reducing downtime in the manufacturing process.
Implementation Method 1
The holder plate may be configured to hold the material by vacuum adsorption
Data Source
AI summary
Described is a device for automatically connecting a continuously manufactured material, the device including a fixed roller rotatably fixed, the fixed roller being rotatable about the shaft of the fixed roller, a swing roller connected to the fixed roller and rotatable by the rotation of the fixed roller, the swing roller being rotatable about the shaft of the swing roller, and a holder plate, connected to the fixed roller, rotatable together with the fixed roller, and configured to hold the material. Also described are a system and a method for manufacturing a material.