Electrode Splicing Alignment Using EPC Sensors for Stable Battery Feed
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Solution Overview
Problem
Existing technologies lack an apparatus capable of stably and successively supplying electrodes in various processes for manufacturing secondary batteries, and there is a need to prevent distortion or fracture defects due to positional deviations between traveling and standby electrodes.
Innovation Solution
An automatic electrode supply apparatus and method utilizing chuck splicing units with edge position control (EPC) sensors to measure and correct positional deviations, incorporating splicing plates with suction holes and electrode cutters to align and connect electrodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional electrode supply methods are used, then electrode supply is possible, but productivity is reduced and process defect rate increases due to inability to stably and successively supply electrodes
Solution Approach 1:
The system divides the electrode supply function into multiple independent chuck splicing units (first, second, third units), each capable of holding and supplying electrodes separately. This segmentation allows one unit to supply electrodes while others are being prepared or replaced, ensuring continuous supply without interruption to productivity while maintaining stability through redundancy.
Solution Approach 2:
The chuck splicing units are pre-loaded with multiple electrodes before the supply process begins. The EPC sensors are pre-positioned to detect electrode edges. This preliminary preparation ensures that when an electrode is consumed, the system can immediately switch to the next pre-loaded electrode without stopping the manufacturing process, maintaining both productivity and reliability.
2Productivity
If electrode supply speed is increased, then productivity improves, but positional deviation between traveling and standby electrodes increases causing distortion or fracture defects
Solution Approach 1:
EPC (Edge Position Control) sensors are installed in each chuck splicing unit to continuously detect the position of electrode edges. The system uses this real-time feedback information to dynamically adjust the position of the chuck splicing units, ensuring that the traveling electrode and standby electrode are precisely aligned even at high supply speeds, thus preventing positional deviation defects while maintaining high productivity.
Solution Approach 2:
The system replaces manual or simple mechanical alignment methods with an automated control system that uses EPC sensors to detect electrode positions and a controller to coordinate the chuck splicing units. This substitution of mechanical alignment with sensor-based feedback control enables precise positioning at high speeds, resolving the contradiction between supply speed and position accuracy.
3Manufacturing precision
If electrode alignment is improved to prevent defects, then manufacturing precision increases, but production time increases due to alignment procedures
Solution Approach 1:
The system maintains continuous electrode supply through multiple chuck splicing units operating in parallel. While one unit is supplying the traveling electrode, other units are simultaneously preparing standby electrodes with their EPC sensors already positioned. The controller coordinates seamless transitions between units, ensuring that alignment and electrode supply occur continuously without interruption or time loss, achieving both high precision and high efficiency.
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
The apparatus enables stable and successive electrode supply, minimizing production time loss and preventing electrode distortion or fracture by accurately aligning traveling and standby electrodes.
Implementation Method 1
each of the first and second chuck splicing units includes an edge position control (EPC) sensor configured to measure a position of an edge of a corresponding one the traveling electrode and the standby electrode
Implementation Method 2
a splicing plate configured to hold the electrode, wherein the splicing plate includes an upper plate and a lower plate
Data Source
AI summary
An automatic electrode supply apparatus configured to automatically supply an electrode in various processes for manufacturing a secondary battery includes a first chuck splicing unit including a splicing portion having a traveling electrode located thereon and a second chuck splicing unit including a splicing portion having a standby electrode located thereon, wherein each of the first and second chuck splicing units includes an edge position control (EPC) sensor configured to measure the position of the edge of a corresponding one of the traveling electrode and the standby electrode in order to prevent distortion or fracture defect of the electrode due to positional deviation between the traveling electrode and the standby electrode, and an automatic electrode supply method using the same.