Electrode Laminate Manufacturing Apparatus Conveyor Meandering Correction
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Solution Overview
Problem
Existing manufacturing apparatuses for electrode laminates face challenges in accurately positioning electrodes between separators due to conveyor belt meandering, leading to positional displacements and reduced joining accuracy.
Innovation Solution
The apparatus includes a conveyor belt system with image pickup units to detect positional displacements and a storage unit to store movement data, allowing for correction of electrode and joining target positions to compensate for belt meandering, ensuring precise placement and joining of electrodes between separators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conveyor belt is used to transport separator materials and electrodes, then productivity is improved through continuous manufacturing, but manufacturing precision deteriorates due to conveyor belt meandering causing positional displacement
Solution Approach 1:
The patent employs image pickup units to detect the actual positions of separator materials and electrodes on the conveyor belt, and uses these detection results to calculate corrected target positions that compensate for conveyor belt meandering. This feedback mechanism allows the system to maintain high positioning accuracy despite the continuous movement and inherent instability of the conveyor belt, thus resolving the contradiction between continuous manufacturing and positioning precision.
Solution Approach 2:
The patent dynamically adjusts the target position parameters for electrode placement and joining operations based on detected conveyor belt position variations. By changing the target position parameters in real-time according to actual conveyor belt conditions, the system maintains manufacturing precision while continuing to operate in a continuous manufacturing mode.
2Manufacturing precision
If electrode target position is corrected based on separator material position, then manufacturing precision is improved, but device complexity increases due to additional image pickup units and position calculation systems
Solution Approach 1:
The image pickup units in the patent serve multiple functions: they detect separator material positions, detect electrode positions, and provide data for calculating corrected target positions. This multi-functionality reduces the need for separate dedicated sensors for each detection task, thereby limiting the increase in device complexity while achieving high manufacturing precision.
Solution Approach 2:
The control unit acts as an intermediary that processes detection data from image pickup units and calculates corrected target positions. Rather than having separate complex systems for detection and correction, the control unit integrates these functions, managing the complexity centrally while enabling precise electrode placement through coordinated position corrections.
3Manufacturing precision
If joining head position is corrected based on electrode position, then manufacturing precision is improved, but loss of time increases due to additional position detection and correction steps
Solution Approach 1:
The system performs position detection and correction calculations in advance during the electrode transport phase, so that when the joining head needs to operate, the corrected target position is already determined. This preliminary action minimizes the time penalty for position correction, as the corrections are prepared concurrently with electrode placement rather than adding sequential delays to the joining process.
Solution Approach 2:
The image pickup units continuously monitor the positions of separator materials and electrodes throughout their transport on the conveyor belt, and the control unit continuously calculates corrected target positions. This continuous operation ensures that position corrections are always up-to-date without requiring separate intermittent measurement steps, thereby maintaining manufacturing precision while minimizing time loss.
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 solution effectively suppresses positional displacements between separators and electrodes, enabling high-accuracy joining and improving manufacturing efficiency by accounting for conveyor belt movement, thus enhancing the production of electrode laminates.
Implementation Method 1
a first image pickup unit configured to detect, as a first positional displacement amount, a positional displacement amount of the first separator material in a lateral direction orthogonal to a traveling direction of the conveyor belt with respect to a first reference position by capturing an image of the first separator material supplied onto the conveyor belt at a first position
Implementation Method 2
a second image pickup unit configured to detect, as a second positional displacement amount, a positional displacement amount in the lateral direction of the electrode with respect to a second reference position by capturing an image of the electrode supplied onto the first separator material at a third position
Data Source
AI summary
An electrode supply unit corrects an electrode target position based on a positional displacement amount of a first separator material, a first offset amount which is an actual positional displacement amount between the first separator material and an electrode when the first separator material is supplied in a manner that a positional displacement is not generated, and a movement amount in a lateral direction when an electrode supply region moves from a first position T1 to a second position T2 The electrode supply unit then supplies the electrode to the first separator material. A joining head corrects a joining target position based on a positional displacement amount of the electrode, a second offset amount which is an actual positional displacement amount which occurs when positions of the electrode and the joining head are adjusted so as not to cause positional displacement, and a movement amount in the lateral direction when the electrode supply region moves from the third position T3 to the fourth position T4. The joining head then joins the separator materials.