Electrode Coating Alignment Correction Using Closed-Loop Sampling
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Solution Overview
Problem
The production process of batteries is complex, and coating deviations can significantly affect battery performance, leading to increased product defects and manufacturing costs if not corrected promptly.
Innovation Solution
A method and apparatus for correcting coating deviations by determining a target deviation correction amount based on acquired distances from coating regions on both surfaces of an electrode plate substrate, using preset correction amounts and closed-loop logic to ensure alignment within specification ranges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If coating deviation is not corrected, then manufacturing process is simple, but battery performance deteriorates and product defects increase
Solution Approach 1:
The system performs preliminary measurement of coating layer thickness and position before the coating process completes, identifies deviations early, and calculates correction amounts in advance. This allows the coating head to be adjusted proactively before defects occur, maintaining battery performance without requiring complex post-processing intervention systems.
Solution Approach 2:
The system implements a closed-loop feedback mechanism where the measurement unit continuously monitors coating layer parameters, compares them against standard values, and automatically adjusts the coating head position based on calculated correction amounts. This real-time feedback control ensures consistent battery performance while keeping the correction system relatively simple through automated control.
2Measurement precision
If multiple sampling points are used to measure coating deviation, then measurement accuracy improves, but measurement time and processing complexity increase
Solution Approach 1:
The measurement process is segmented into multiple independent sampling points across the coating region. Each sampling point is measured separately by the measurement unit, allowing parallel data collection that improves overall measurement accuracy without significantly increasing total measurement time, as the segmentation enables systematic and efficient data gathering.
Solution Approach 2:
The system measures coating parameters at multiple sampling points, which is an excessive action beyond the minimum single-point measurement. This partial/excessive measurement approach ensures that even if some sampling points have measurement variations, the overall coating deviation assessment remains highly accurate, meeting the precision requirement while managing time through efficient multi-point simultaneous measurement capability.
3Ease of manufacture
If coating misalignment exceeds specification range, then manufacturing cost increases due to defects, but simple measurement without correction keeps process simple
Solution Approach 1:
The coating system performs self-correction through the automated feedback loop. The measurement unit detects alignment deviations, the control unit calculates correction amounts, and the coating head automatically adjusts its position without external intervention. This self-service capability ensures manufacturing precision is maintained while avoiding the costs associated with manual correction or defective product disposal.
Data Source
AI summary
A coating deviation correction method includes acquiring a plurality of first distances and a plurality of second distances, where each of the plurality of first distances is a distance from an edge of a coating region on a first surface of an electrode plate substrate to a reference edge, each of the plurality of second distances is a distance from an edge of a coating region on a second surface of the electrode plate substrate to the reference edge, and the plurality of first distances and the plurality of second distances are obtained by sampling a plurality of times within one sampling period; and determining a target deviation correction amount in a coating process based on the plurality of first distances, the plurality of second distances, and at least one preset deviation correction amount.