Battery Electrode Roll Press Feedback Control for Thickness Uniformity
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Solution Overview
Problem
Existing roll press devices for secondary battery electrode plates struggle with thickness accuracy of 2 μm or less, leading to facility operation rate decreases and yield losses due to thickness variations caused by processing heat or bearing heat, which are exacerbated by the need for manual adjustments and material removal.
Innovation Solution
A roll press device equipped with a first and second pressure roller, bearings, compression and bend mechanisms, a thickness meter, and a controller that adaptively adjusts load settings based on real-time thickness measurements to maintain precise thickness control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual adjustment of press conditions is performed to correct thickness deviations, then thickness control accuracy can be improved, but facility operation rate decreases due to line stoppages
Solution Approach 1:
A thickness meter measures the thickness of the electrode plate at multiple positions in the width direction, and a calculator automatically computes correction values based on measured deviations from the target thickness. The controller then adjusts the press conditions of compression and bend mechanisms in real-time without stopping the production line, achieving both high thickness accuracy and continuous operation
Solution Approach 2:
The system performs self-adjustment of press conditions through automated feedback control. The thickness meter continuously monitors electrode plate thickness, and the controller automatically modifies compression and bend forces based on real-time measurements, eliminating the need for manual intervention and line stoppages while maintaining thickness accuracy
2Manufacturing precision
If manual removal of excess thickness portions is performed, then thickness control accuracy can be improved, but yield decreases due to material loss
Solution Approach 1:
The thickness meter measures electrode plate thickness at multiple positions, and the calculator automatically determines the necessary correction amounts for compression and bend mechanisms. This real-time feedback control adjusts press conditions to achieve target thickness without exceeding it, eliminating the need to remove excess material and preventing yield loss
Solution Approach 2:
The system performs preliminary adjustment of press conditions before thickness deviations become excessive. By continuously monitoring thickness and proactively adjusting compression and bend forces, the system prevents the formation of excessive thickness portions that would require material removal, thereby maintaining both accuracy and yield
3Quantity of substance
If electrode length is increased to achieve higher battery capacity, then battery capacity increases, but thickness variations become more significant due to manufacturing tolerances
Solution Approach 1:
The thickness meter measures thickness at multiple positions across the width direction of the electrode plate, and the controller adjusts press conditions locally for different regions. The compression and bend mechanisms are controlled independently to address thickness variations at specific locations, enabling high thickness uniformity across the entire electrode surface even at increased lengths
Solution Approach 2:
The system dynamically adjusts press conditions during production based on real-time thickness measurements. The controller continuously modifies compression and bend forces according to actual thickness deviations detected by the thickness meter, enabling adaptive control that maintains high thickness uniformity across varying electrode lengths and production conditions
Data Source
AI summary
A thickness meter detects a thickness of an electrode plate of a secondary battery at three or more points in a width direction of the electrode plate. A calculator calculates three feature amounts of a first deviation between the thickness target value and a thickness measurement value of a point closest to a first compression mechanism among the three or more points, a second deviation between the thickness target value and a thickness measurement value of a point closest to a second compression mechanism among the three or more points, and a secondary component of a thickness profile of the electrode plate from thickness measurement values at the three or more points and the thickness target value, and adaptively changes the setting values of the first compression mechanism, the second compression mechanism, a first bend mechanism, and a second bend mechanism on the basis of the three feature amounts.