Dual Stacking Wheels for Damage-Free Flat Item Stacking
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Solution Overview
Problem
Existing stacking methods for flat items like electrodes in electrochemical energy stores or energy converters, such as lithium-ion batteries and fuel cells, face inefficiencies and damage risks due to the use of conventional stacking wheels that deform and brake the items, leading to incomplete stacking and increased manufacturing bottlenecks.
Innovation Solution
A device with dual stacking wheels having aligned shafts and compartments that vary their opening geometry during rotation, allowing for controlled insertion, braking, and removal of flat items without damage, using congruent compartments and congruent stacking fingers to ensure secure stacking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If highly curved compartments are used in stacking wheels to brake conveying speed, then braking effect is improved, but flat items become damaged and cannot be inserted completely
Solution Approach 1:
The invention divides the braking function into two separate stacking wheels instead of one wheel with highly curved compartments. The first stacking wheel provides initial braking with gentle curvature, while the second stacking wheel provides additional braking. This segmentation allows the braking force to be distributed over a longer period and reduced intensity, preventing damage to the flat items while still achieving the necessary speed reduction for stacking.
2Productivity
If conventional stacking wheels with highly curved compartments are used, then stacking function is achieved, but manufacturing throughput is limited due to incomplete insertion and damage
Solution Approach 1:
The stacking function is segmented across two stacking wheels with parallel shafts. Each wheel has compartments that work in sequence, allowing flat items to be gradually guided and stacked without forced insertion. This segmented approach improves reliability by ensuring complete insertion while maintaining high conveying speeds, thus increasing manufacturing throughput.
Solution Approach 2:
The invention introduces dynamic interaction between two rotating stacking wheels with parallel shafts. The wheels rotate in the same direction at the same speed, creating a dynamic opening between compartments that adapts to the flat items during the stacking process. This dynamic mechanism allows continuous operation at high speed while ensuring reliable stacking completion.
3Manufacturing precision
If single stacking wheel is used, then device complexity is low, but stacking precision and control are insufficient
Solution Approach 1:
The stacking precision is improved by segmenting the stacking function into two wheels. Each wheel contributes to the overall precision control, with the first wheel handling initial positioning and the second wheel completing the stacking. This segmentation allows for better control and precision without requiring overly complex individual components.
Solution Approach 2:
The two stacking wheels are arranged with parallel shafts at a specific distance, creating an asymmetric configuration optimized for the stacking process. The shafts are positioned such that their central points lie in a plane, with the distance between shafts creating an optimal opening geometry for compartment interaction. This asymmetric arrangement provides precise control while maintaining reasonable device complexity.
Data Source
AI summary
A device for stacking flat items has stacking wheels which have stacking fingers and, located between the stacking fingers, compartments for receiving flat items to be stacked, a conveying device for conveying the flat items into the compartments of the stacking wheels, a stripper for removing the flat items from the compartments of the stacking wheels, a support for receiving the flat items removed from the compartments of the stacking wheels and for forming a stack of flat items, in which at least one first stacking wheel mounted on a first shaft and at least one second stacking wheel mounted on a second shaft are provided.