Electrode Rolling Reconnection Using Tension Sensing and Stoppers
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Solution Overview
Problem
The existing battery manufacturing processes face significant productivity issues due to electrode disconnections during the rolling process, which require operators to stop the manufacturing equipment for reconnection, leading to reduced operation rates and productivity.
Innovation Solution
A battery manufacturing device equipped with a fixed roller, tension sensors, and stoppers that detect and respond to tension abnormalities by moving to reposition and reconnect disconnected electrodes without halting the manufacturing process, utilizing moving rollers and stoppers to guide the electrode back onto the rolling path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a rolling process is performed to increase the density of active material on the electrode, then the energy density of the battery is improved, but the electrode may become disconnected due to stress concentration at step portions
Solution Approach 1:
The tension sensor detects tension abnormalities in advance before complete disconnection occurs, and the stopper is pre-positioned to intervene and prevent disconnection. This preliminary detection and prevention mechanism addresses the contradiction by maintaining electrode integrity while preserving the rolling process for density enhancement.
2Reliability
If the manufacturing process is stopped to reconnect disconnected electrodes, then the electrode connection reliability is improved, but the productivity and operation rate of the manufacturing equipment deteriorate
Solution Approach 1:
The system performs self-diagnosis through the tension sensor to detect electrode abnormalities, and the stopper automatically intervenes to prevent disconnection without requiring external operator intervention or process shutdown. This self-monitoring and self-correction mechanism maintains both reliability and productivity.
Solution Approach 2:
The tension sensor provides continuous feedback on electrode tension status, enabling real-time detection of abnormalities. This feedback loop allows the system to respond immediately to potential disconnections, maintaining electrode reliability while keeping the manufacturing process running continuously.
3Reliability
If tension sensors and stoppers are added to detect and prevent electrode disconnection, then the electrode connection reliability is improved, but the device complexity increases
Solution Approach 1:
The tension sensor acts as an intermediary detection device that monitors electrode tension without interfering with the rolling process. The stopper serves as a mechanical intermediary that physically prevents disconnection. These intermediary elements add minimal complexity while significantly improving reliability.
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 prevents electrode detachment and allows continuous operation of the manufacturing device, enhancing productivity by enabling seamless reconnection of disconnected electrodes without stopping the process, thus improving overall manufacturing efficiency.
Implementation Method 1
a tension sensor that detects a tension variation of the electrode
Implementation Method 2
a stopper that is disposed between the fixed roller and the roller, and when the electrode is disconnected, moves the disconnected electrode
Data Source
AI summary
The present invention relates to a battery manufacturing device including: a fixed roller that moves an electrode where an active material is applied; a roller that rolls the electrode; and a stopper that is disposed between the fixed roller and the roller, and when the electrode is disconnected, moves the disconnected electrode.