Electrode Coating Thickness Measurement Before Drying
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Solution Overview
Problem
Existing methods for measuring electrode plate thickness in secondary batteries are inadequate for rapid detection of coating failures, particularly due to thermal deformation of sensors, which complicates the control of electrode plate thickness during the manufacturing process.
Innovation Solution
An apparatus and method using a sensor module with first and second sensors to measure electrode plate thickness before drying, compensating for thermal deformation errors by calculating and interpolating measurement errors, and determining coating failures through threshold comparisons.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a radiation device is used to measure electrode plate thickness behind a drying furnace, then thickness measurement is possible, but coating failure cannot be rapidly checked
Solution Approach 1:
The sensor module measures electrode plate thickness before the drying furnace processes the plate. By performing measurement in advance (upstream of the drying furnace), the system enables rapid detection of coating failures without waiting for the drying process to complete, thus improving productivity while maintaining measurement precision.
2Productivity
If a sensor module is placed upstream of the drying furnace to enable rapid measurement, then coating failure detection speed improves, but measurement accuracy deteriorates due to thermal deformation
Solution Approach 1:
The processor continuously monitors thickness measurements from the sensor module and compares them against reference values or predetermined thresholds. This feedback mechanism enables real-time detection of coating failures while compensating for thermal deformation effects through comparative analysis, thus maintaining measurement precision despite the upstream positioning of the sensor.
Solution Approach 2:
The patent replaces traditional radiation-based thickness measurement with a sensor module that operates upstream. This substitution allows measurement in a location that enables rapid coating failure detection while the processor compensates for thermal effects through computational methods rather than mechanical adjustments.
3Loss of time
If measurement is performed upstream of the drying furnace, then rapid coating failure detection is enabled, but thermal deformation of the sensor module causes measurement errors
Solution Approach 1:
The processor uses feedback control to continuously monitor thickness measurements and compare them with expected values. This allows real-time detection of coating failures while compensating for thermal deformation errors through iterative correction based on measured deviations from reference standards.
Solution Approach 2:
The system compensates for thermal deformation by dynamically adjusting measurement parameters or applying correction factors based on temperature conditions. The processor modifies the interpretation of sensor readings to account for thermal expansion or contraction of the sensor module, thus maintaining measurement precision despite temperature variations upstream of the drying furnace.
Data Source
AI summary
An apparatus and method for measuring an electrode plate thickness, which can measure a thickness of an active-material-coating layer formed on an electrode plate before drying the electrode plate. The apparatus for measuring an electrode plate thickness includes a sensor module configured to detect a thickness of an electrode plate upstream of a drying furnace, and a processor connected to the sensor module, and configured to detect the thickness of the electrode plate in a width direction through the sensor module, calculate an active-material-coating thickness based on the thickness of the electrode plate, and compensate the active-material-coating thickness based on a measurement error due to thermal deformation of the sensor module.