Electrochemical Stack Assembly Using Measured Component Heights
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing production systems for electrochemical systems with stacked components face challenges in achieving a target height due to component tolerances, leading to additional costs and extended production time as stacks often need to be unstacked and rearranged to meet height requirements.
Innovation Solution
A production system that determines and stores height values of components, automatically reads out these values, and uses them to assemble stacks, incorporating compensating elements or dummy cells to achieve a target height, ensuring the stack meets tolerance ranges through automated processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If components are stacked based on nominal height values without considering individual tolerances, then the stacking process is simple and fast, but the final stack height may fall outside the permissible tolerance range
Solution Approach 1:
The system measures and records the actual height of each component before stacking. This preliminary action allows the control unit to calculate the cumulative height and select components that will achieve the target stack height within tolerance, avoiding the need for rework later
Solution Approach 2:
The system changes the parameter consideration from nominal height values to actual measured height values. By using the actual height data of each component, the control unit can make precise selections to ensure the final stack meets height requirements
2Productivity
If stacks are produced and then checked for height tolerance, then production flow is continuous, but stacks outside tolerance must be unstacked and rearranged causing additional time and costs
Solution Approach 1:
The system performs the height calculation and component selection before the stacking process completes. By determining the exact combination of components that will achieve the target height, the system prevents the need for unstacking and rearranging later
Solution Approach 2:
The control unit uses feedback from the actual height measurements of components to dynamically adjust the stacking sequence and selection. This closed-loop approach ensures the final stack meets specifications without requiring post-production adjustments
3Manufacturing precision
If components are manually selected and arranged to achieve target height, then stack height precision is improved, but labor costs and production time increase
Solution Approach 1:
The system replaces manual visual inspection and selection with an automated measurement and control system. Optical sensors or laser measurers automatically capture component heights, and the control unit algorithmically determines the optimal stacking sequence, achieving both precision and efficiency
Solution Approach 2:
The system enables components to 'self-report' their actual height through automated measurement. Each component's height data is automatically captured and used by the control unit to determine its position in the stack, eliminating the need for manual measurement and selection
Data Source
AI summary
The present disclosure relates to a production system for producing at least one electrochemical system that comprises a stack consisting of a plurality of different components which are stacked one above the other along a stacking axis of the stack, with a height dimension of each component extending along the stacking axis where the production system allows the target height of the stack to be achieved in spite of the height tolerances of the different components.