Automated Electrode Roll Replacement System
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Solution Overview
Problem
The existing methods for replacing electrode rolls in secondary battery production are limited by weight constraints due to the need for human intervention, which restricts the winding amount and equipment utilization.
Innovation Solution
An electrode roll replacement system with electrically operated transfer mechanisms on the air chuck shaft and transport shaft, allowing automated exchange of bobbins without human intervention, using conveyor belts or pinion gears for smooth transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If human labor is used to replace electrode rolls, then the replacement process is simple and low-cost, but the winding amount is limited by weight constraints and equipment utilization is reduced
Solution Approach 1:
The system enables automated self-service replacement of electrode rolls through the automated cart that autonomously navigates to the unwinder, positions itself, and executes the roll exchange using robotic manipulators, eliminating the need for human operators to manually handle heavy rolls
Solution Approach 2:
The patent replaces manual mechanical handling with an automated electromechanical system comprising a programmable cart, robotic manipulators with grippers, and control systems that coordinate the replacement process, substituting human physical labor with automated machinery
2Productivity
If larger electrode rolls are used to increase winding amount, then equipment utilization improves, but the weight exceeds human lifting capabilities
Solution Approach 1:
The automated cart system performs self-service by autonomously transporting and installing heavy electrode rolls without human intervention, using sensors for navigation, robotic manipulators for handling, and programmable control logic to execute the entire replacement sequence
Solution Approach 2:
The automated cart acts as an intermediary between the storage area and the unwinder, serving as a mobile platform that bridges the gap between heavy roll storage and the processing equipment, enabling weight exceedance beyond human limits through mechanical assistance
3Productivity
If shorter replacement cycles are implemented to increase productivity, then equipment utilization improves, but the complexity of coordination and precision requirements increase
Solution Approach 1:
The system implements feedback control through sensors that monitor the cart's position, the manipulators' gripper closure, the roll alignment with the unwinder shaft, and the completion of each replacement step, allowing real-time adjustments to maintain precision during rapid operations
Solution Approach 2:
The automated cart is designed as a multi-functional universal platform that combines navigation, transport, positioning, and manipulation capabilities in a single integrated system, reducing overall system complexity compared to separate specialized devices for each function
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
Enables increased winding amount of electrode rolls and improves equipment utilization by eliminating weight limitations through automated bobbin transfer.
Implementation Method 1
movement of the bobbin occurs by frictional forces acting between the conveyor belt and an inner circumferential surface of the bobbin
Implementation Method 2
movement of the bobbin occurs by engagement of the pinion gear with a rack gear formed on an inner circumferential surface of the bobbin
Data Source
Figure 1
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AI summary
The disclosed electrode roll replacement system including: an air chuck shaft in the form of a cantilever, comprising a first transfer mechanism installed inside a hollow with a longitudinal direction of a shaft as a transfer direction, and exposing a first transfer surface of the first transfer mechanism on its surface; and an electric cart provided with a transportation shaft in the form of a cantilever, including a second transfer mechanism installed inside a hollow with a longitudinal direction of a shaft as a transfer direction, and exposing a second transfer surface of the second transfer mechanism on its surface, wherein the first and second transfer mechanisms are electrically operated to exchange bobbins between the air chuck shaft and the transport shaft, with the transport shaft of the electric cart concentrically aligned with the air chuck shaft.