Electrode Assembly Alignment Using Vision-Measured Unit Cell Width
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Solution Overview
Problem
In the manufacturing of stack/folding type electrode assemblies for secondary batteries, irregular distances between unit cells can lead to position errors and misalignment during lamination, causing issues with charging and overcharging due to gaps between misaligned overhang portions.
Innovation Solution
A method involving a unit cell grasping step, vision measurement of the full width value of each unit cell, and precise adjustment using a movable gripper to seat the unit cells on a separation film, ensuring accurate alignment and preventing gap tolerance by reflecting actual measurements rather than predetermined design values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If predetermined design values are used for unit cell width, then manufacturing process is simple, but position error and misalignment occur during lamination
Solution Approach 1:
The vision measurement system measures the full width value of each unit cell before the lamination process, and the movable gripper adjusts the position in advance. This preliminary measurement and adjustment prevents position errors during lamination, ensuring accurate alignment without adding complex real-time control systems.
Solution Approach 2:
The system uses a vision measurement system to detect the actual full width value of each unit cell, compares it with the set width value, and provides feedback to the movable gripper for position adjustment. This closed-loop feedback mechanism ensures accurate alignment while maintaining relatively simple device architecture.
2Reliability
If actual full width measurement is implemented for each unit cell, then gap tolerance between unit cells is prevented, but measurement and control system complexity increases
Solution Approach 1:
The vision measurement system measures the actual full width value of each unit cell and provides feedback to the control system. The movable gripper then adjusts the position based on the width difference between measured and set values, ensuring accurate spacing and preventing gap tolerance that could cause charging reliability issues.
Solution Approach 2:
The patent replaces complex mechanical measurement systems with a vision measurement system that uses optical fields to measure unit cell dimensions. This substitution simplifies the measurement mechanism while achieving high precision in detecting full width values and ensuring reliable charging operation.
3Productivity
If unit cells are laminated without width adjustment, then manufacturing process is fast, but overhang and misalignment occur causing charging issues
Solution Approach 1:
The system performs vision measurement and position adjustment of each unit cell before the lamination process. The movable gripper corrects width differences in advance, ensuring accurate alignment is achieved before units are laminated together, preventing overhang and charging issues while maintaining efficient production flow.
Solution Approach 2:
The movable gripper acts as an intermediary device between the vision measurement system and the lamination process. It receives measurement data, calculates position adjustments based on width differences, and physically adjusts unit cell positions before lamination, ensuring alignment precision without slowing down the overall manufacturing process.
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 approach allows for real-time measurement and correction of unit cell widths, preventing overhang and ensuring proper lamination gaps, thereby enhancing the reliability and efficiency of the electrode assembly manufacturing process.
Implementation Method 1
a vision measurement step of vision-measuring a full width value of the unit cell
Data Source
AI summary
A method for manufacturing an electrode assembly includes a unit cell grasping step of moving a movable gripper to grasp a unit cell having an electrode and a separator, a vision measurement step of vision-measuring a full width value of the unit cell, and an input step of determining a width difference between the full width value of the unit cell and a set width value stored in a memory, and moving the unit cell by the movable gripper while taking into account the width difference to seat the unit cell on the separation film. A method for manufacturing a secondary battery includes a manufacturing step of manufacturing an electrode assembly according to the above, and an accommodation step of accommodating the folded electrode assembly in a battery case.