Electrode Stack Alignment Using a Movable Stacking Wheel Guide
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Solution Overview
Problem
The existing methods for stacking flat electrode elements in electrochemical energy stores and fuel cells face bottlenecks in manufacturing throughput due to limited accuracy and speed, particularly in the production of lithium-ion batteries, where the alignment of electrode elements is not precise enough to enhance the performance of the energy stores or converters.
Innovation Solution
A method and device that utilize a movable alignment element, external to the stacking wheel, to accurately position flat electrode elements laterally during the stacking process, allowing for precise alignment with an accuracy of at least ±0.2 mm, which increases the stacking accuracy and performance of the energy stores or converters by using an actively movable alignment element that can be coupled with an actuator and vibrates or moves axially to guide the electrode elements to their target positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a gripper arm of a robot is used to grip and place electrode elements, then the stacking process can be performed, but a significant increase in speed is no longer to be expected and manufacturing throughput is limited
Solution Approach 1:
The patent transitions from a static gripper arm system to a dynamic rotating stacking wheel system. The stacking wheel rotates about a rotation axis, dynamically transporting electrode elements through intermediate spaces formed by stacking fingers. This dynamic mechanism enables continuous high-speed stacking operations, resolving the contradiction between productivity and speed by implementing a motion-based stacking approach rather than sequential pick-and-place operations.
Solution Approach 2:
The patent implements preliminary alignment of electrode elements using movable alignment elements before the actual stacking operation. The alignment elements actively move laterally to position electrode elements precisely in the stacking position during transport. This preliminary action ensures accurate stacking without requiring slow, precision-adjusted gripper operations, thereby increasing both speed and productivity while maintaining precision.
2Manufacturing precision
If conventional stacking methods are used, then electrode elements can be stacked, but stacking accuracy is not precise enough to enhance the performance of energy stores or converters
Solution Approach 1:
The patent replaces conventional mechanical alignment mechanisms with actively movable alignment elements that are coupled with actuators. These alignment elements can vibrate or move axially to guide electrode elements to their target positions with high precision (at least ±0.2 mm). This substitution of passive mechanical systems with active controlled systems resolves the contradiction by enabling precise stacking without sacrificing productivity, as the active alignment occurs during the transport phase rather than requiring separate positioning steps.
3Manufacturing precision
If a rotating stacking wheel is used to convey electrode elements, then stacking can be performed, but lateral alignment accuracy is insufficient without additional alignment mechanisms
Solution Approach 1:
The patent integrates movable alignment elements directly into the stacking wheel system, making the stacking wheel perform multiple functions: transporting electrode elements, providing intermediate storage spaces, and enabling lateral alignment through the integrated alignment elements. This multi-functionality resolves the contradiction by adding alignment capability without requiring a completely separate alignment device, thus improving lateral alignment accuracy while limiting the increase in overall device complexity.
Data Source
AI summary
A method is provided for producing an electrode stack with flat electrode elements, including: a) providing a first electrode element; b) inserting the first electrode element into an intermediate space formed by stacking fingers of a stacking wheel which rotates about a rotation axis; c) transporting the first electrode element with the stacking wheel; d) removing the first electrode element from the intermediate space; e) arranging the first electrode element in a stacking position; f) providing a second electrode element; g) inserting the second electrode element into a further intermediate space different from the intermediate space and formed by stacking fingers of the stacking wheel; h) removing the second electrode element from the further intermediate space; and i) arranging the second electrode element in the stacking position and producing the electrode stack. The first electrode element is moved to a lateral target position by a movable alignment element.