Electrode Assembly Stacking Alignment Using Vision-Based Error Detection
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Solution Overview
Problem
The stacked type electrode assembly in secondary batteries faces issues with non-uniform stacking of radical units, leading to potential defects and short circuits.
Innovation Solution
A method and apparatus for manufacturing electrode assemblies that involve precise measurement and alignment of radical units using vision alignment testers and measuring members to ensure accurate stacking, with error detection and adjustment processes to correct positional discrepancies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If radical units are stacked manually or by conventional methods, then the manufacturing process is simple, but the stacking alignment is poor leading to defects
Solution Approach 1:
The patent measures the position of each radical unit before stacking to predict potential alignment issues in advance. The vision alignment tester captures images of radical units at predetermined positions, and the controller calculates expected positions and differences before the actual stacking occurs, allowing preventive correction rather than reactive adjustment.
Solution Approach 2:
The system continuously monitors radical unit positions during the stacking process by capturing images at multiple predetermined positions. The controller calculates position differences between consecutive radical units and provides feedback to adjust the stacking process, ensuring alignment remains within specified tolerances throughout manufacturing.
2Manufacturing precision
If multiple measurement steps are implemented to ensure stacking alignment, then stacking precision is improved, but the manufacturing time increases
Solution Approach 1:
The vision alignment tester captures images of radical units at periodic intervals at predetermined positions during the stacking process. This periodic measurement approach ensures adequate monitoring of alignment without requiring continuous measurement, thereby maintaining manufacturing speed while ensuring precision.
Solution Approach 2:
The patent replaces complex mechanical measurement systems with a vision-based alignment testing system that uses cameras and image processing. This substitution enables rapid, non-contact measurement of radical unit positions, significantly reducing measurement time compared to traditional mechanical methods while maintaining high precision.
3Reliability
If the position of each radical unit is measured and controlled, then stacking defects are prevented, but the device complexity and cost increase
Solution Approach 1:
The patent introduces a vision alignment tester as an intermediary device between the radical units and the stacking mechanism. This intermediary captures images and provides positional information to the controller, which then adjusts the stacking process accordingly, enabling defect prevention without requiring direct complex interaction between measurement and stacking systems.
Solution Approach 2:
The system creates optical copies (images) of radical units using the vision alignment tester at predetermined positions. These image copies are processed by the controller to determine positional accuracy without requiring physical contact or complex mechanical measurement apparatus, thereby maintaining reliability while reducing device complexity.
Data Source
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AI summary
The present invention relates to a method for manufacturing an electrode assembly. The method for manufacturing the electrode assembly comprises: a step (a) of transferring a plurality of radical units one by one from a first set position to a second position; a step (b) of measuring a distance between a full width end that is an end of the first electrode in a full width direction and a full width end that is an end of the second electrode in a full width direction; a step (c) of measuring a distance (B1) from a reference point (O) of the second set position to the full width end of the first electrode of the first radical unit; a step (d) of stacking the second radical unit on the first radical unit; a step (e) of measuring a distance (B2) from the reference point (O) of the second set position to the full width end of the first electrode of the second radical unit; a step (f) of measuring a distance (C1) between the full length end of the first electrode of the first radical unit and the full width end of the second electrode of the second radical unit by adding the distances (B2, A2) to each other and subtracting the distance (B1) from the sum of the distances (B2, A2); and a step (g) of comparing the distances (C1, A1) to each other to determine whether stacking is defective.