Electrode Stacking Alignment Inspection for Early Misalignment Detection
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Solution Overview
Problem
Existing methods for inspecting the alignment of electrode plates in secondary batteries, such as lithium secondary batteries, do not effectively detect misalignment during the stacking process, leading to potential short-circuits and product defects, with current solutions only identifying defects after the assembly is completed.
Innovation Solution
An electrode plate aligned state inspection system that includes a supply unit for alternately transferring cathode and anode plates, a separator supply unit, and an inspection unit to image and inspect the alignment of the plates and separators in real-time, determining misalignment during the stacking process and suspending the process if misalignment exceeds a predetermined distance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If inspection is performed after electrode assembly is completed, then misalignment can be detected, but the completed electrode assembly must be discarded even when only one electrode plate is misaligned
Solution Approach 1:
The inspection unit images and inspects the alignment of electrode plates and separators during the stacking process, before the electrode assembly is completed. This preliminary inspection allows misalignment to be detected early, preventing waste of the entire electrode assembly by enabling corrective action during manufacturing rather than after completion.
2Loss of time
If real-time imaging and inspection during stacking is implemented, then misalignment can be immediately recognized, but the inspection system complexity increases
Solution Approach 1:
The patent replaces complex mechanical measurement systems with an optical imaging system. The inspection unit uses imaging to capture images of the stacking process and inspects alignment by analyzing the images, which simplifies the system structure while enabling real-time detection during the stacking process.
3Reliability
If appearance inspection or charge capacity inspection is performed after electrode assembly completion, then product defects can be determined, but misalignment of electrode plates cannot be inspected
Solution Approach 1:
The inspection unit performs alignment inspection during the stacking process before the electrode assembly is completed. By imaging the stacking process in real-time, the system detects misalignment of electrode plates and separators while they are being assembled, enabling corrective action before final product completion and avoiding the limitation of post-assembly inspection methods.
Data Source
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AI summary
Provided are an electrode aligned state inspection system and method of imaging a stacking process of an electrode plate, inspecting a position of the electrode plate, and determining whether or not a product is defective. When a misalignment occurs during the stacking process of a cathode plate, an anode plate, and a separator, an operator immediately recognizes the occurrence of the misalignment, and therefore, it is possible to improve a quality reliability of the electrode assembly. In addition, since it is determined whether or not the product is defective during a production process of the electrode assembly, an amount of waste may be reduced. The video data obtained by the imaging of the production process of the electrode assembly is automatically stored, and therefore, the data may be used as data that may be checked later when the quality is checked and the defective product is produced.