Electrode Connection Alignment Using Optical Imaging Feedback
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Solution Overview
Problem
In the assembly process of secondary batteries, the alignment of waiting and traveling electrodes often becomes distorted, leading to electrode breakage and reduced operational rates and yields due to manual errors and the limitations of existing alignment sensors.
Innovation Solution
An electrode connection device comprising a first and second electrode supply part, a photographing part, an aligning part, and a connection part, which uses image photography and position adjustment to ensure accurate alignment of patterned and unpatterned regions of the electrodes before connection, employing a prism mirror and light sources for precise alignment and adhesive connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If various sensors such as EPC sensor are disposed to check alignment state using Y-axis meandering detection, then the alignment checking capability is improved, but the electrode breakage still occurs due to inability to detect actual alignment at connection point
Solution Approach 1:
The patent replaces the mechanical sensor-based alignment detection system with an optical imaging system. The imaging device captures images of the electrodes at the connection point, and the image processing unit analyzes these images to determine alignment accuracy. This optical approach directly observes the connection region, eliminating the gap between detection and connection locations that caused electrode breakage with sensor-based systems.
2Ease of operation
If manual preparation of waiting electrode is performed, then flexibility in electrode preparation is improved, but alignment accuracy deteriorates due to worker mistakes causing oblique connection
Solution Approach 1:
The patent replaces manual visual alignment with an automated optical imaging and image processing system. The imaging device captures the electrode positions, and the image processing unit automatically calculates alignment accuracy and provides feedback for correction. This eliminates human error in alignment judgment while maintaining operational flexibility through automated control.
3Productivity
If traveling roller is used to supply traveling electrode, then continuous electrode supply is improved, but meandering occurs causing alignment distortion
Solution Approach 1:
The patent implements a feedback control system where the imaging device continuously monitors the electrode line position during supply, and the image processing unit analyzes the images to detect meandering. The system provides real-time feedback to adjust the traveling roller position or speed, correcting alignment deviations while maintaining continuous supply. This closed-loop control eliminates the alignment distortion caused by roller-induced meandering.
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 device effectively suppresses electrode breakage and enhances operational rates and yields by ensuring accurate alignment without distortion during the connection process, allowing for continuous and reliable electrode supply.
Implementation Method 1
a photographing part photographing images of a connection target region of the first electrode and a connection target region of the second electrode
Data Source
AI summary
An electrode connection device includes a first electrode supply part, a second electrode supply part, a photographing part, an aligning part, and a connection part. The second electrode supply part supplies a second electrode to the first electrode supply part when a supply amount of the first electrode is below a certain level. The photographing part photographs a connection target region of the first electrode and a connection target region of the second electrode and the aligning part aligns the connection target regions of the first and second electrodes. The connection part connects the connection target regions of the first and second electrodes when in an aligned state. A method including the same is also provided.