Electrode Cell Alignment Control Using Vision Sensor Feedback
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Solution Overview
Problem
The manual monitoring and adjustment of electrode sheet and separator sheet alignment in secondary battery manufacturing lead to variations in electrode cell quality due to individual operator skill levels, resulting in inconsistent product quality and increased non-operational losses.
Innovation Solution
An automated apparatus and method utilizing sub-vision sensors to detect and correct the alignment of electrode and separator sheets in real-time during the manufacturing process, including a first detection process, a second detection process, and an output process to identify and address alignment abnormalities, thereby ensuring uniform quality and reducing operational losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual monitoring and adjustment of alignment is used, then operator flexibility is maintained, but manufacturing precision deteriorates due to individual skill variations
Solution Approach 1:
The patent replaces the manual mechanical alignment adjustment system with an automated vision-based detection and control system. Cameras capture images of alignment marks on electrode and separator sheets, and a control unit automatically calculates and adjusts alignment based on image analysis, eliminating dependence on operator skill while maintaining operational flexibility.
Solution Approach 2:
The alignment system performs self-adjustment through automated feedback control. The vision sensor detects alignment deviations, the control unit calculates correction amounts, and the system automatically adjusts the alignment without requiring continuous manual intervention, enabling the system to service itself during operation.
2Manufacturing precision
If automated vision-based alignment detection is implemented, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent introduces alignment marks as intermediary reference elements on the electrode and separator sheets. These marks serve as mediators between the vision system and the physical alignment state, simplifying the detection process by providing clear, easily recognizable targets for the cameras to capture and analyze, thereby reducing overall system complexity.
Solution Approach 2:
The vision system creates optical copies (images) of the alignment marks and electrode/separator structures. By working with these digital copies rather than directly manipulating physical components during detection, the system achieves precise measurement without requiring complex physical measurement apparatus, reducing device complexity while maintaining high precision.
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 apparatus ensures consistent electrode cell quality by automatically detecting and correcting alignment issues, reducing the impact of operator skill variations and minimizing non-operational losses through real-time monitoring and precise alignment control.
Implementation Method 1
a vision sensor positioned at a position corresponding to the alignment mark of the electrode sheet or the alignment mark of the separator sheet among the plurality of vision sensors
Data Source
AI summary
An apparatus for manufacturing an electrode cell is configured to manufacture the electrode cell by stacking and cutting a separator sheet and an electrode sheet. A method for controlling an apparatus for manufacturing an electrode cell includes: a first detection process of inspecting the electrode cell in real time or at a preset period while a process of manufacturing the electrode cell is performed; a second detection process of detecting an alignment of the electrode sheet and the separator sheet; and an output process of outputting information of a position at which abnormality of the alignment is detected in the second detection process when abnormality of the electrode cell is detected in the first detection process.