Electrode Assembly Stacking With Vision-Based Meandering Correction
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Solution Overview
Problem
Conventional stack type electrode assemblies face issues with meandering due to poor positioning accuracy of electrodes and separators, leading to increased manufacturing time and errors.
Innovation Solution
A method and apparatus for manufacturing electrode assemblies that involve precise positioning and correction of electrodes and separators using vision sensors and correction mechanisms to prevent meandering, ensuring accurate stacking and bonding through heat and pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual stacking and combining of electrodes and separators is used, then manufacturing flexibility is maintained, but positioning accuracy deteriorates causing meandering
Solution Approach 1:
The manufacturing process is divided into distinct modules: electrode cutting unit, transfer unit with vision sensor, stacking unit, and bonding unit. Each module performs a specific function, allowing precise control at each stage while maintaining overall process flexibility. The segmentation enables automated positioning without requiring complete automation of the entire process.
Solution Approach 2:
Manual mechanical positioning is replaced with an automated vision sensor system that detects electrode positions and guides the stacking process. The vision sensor captures images, processes coordinates, and automatically adjusts positioning, eliminating manual alignment errors while keeping the mechanical stacking mechanism simple and flexible.
2Productivity
If electrode traveling distance is increased to accommodate longer manufacturing lines, then production capacity is improved, but meandering frequency increases
Solution Approach 1:
The vision sensor provides real-time feedback on electrode positions during the stacking process. The system captures images, processes the coordinates to determine actual positions, and uses this feedback to adjust positioning dynamically. This closed-loop control maintains positioning accuracy regardless of electrode traveling distance or swell variations.
Solution Approach 2:
The positioning system is designed to be dynamic rather than static. The vision sensor continuously monitors electrode positions, and the system adapts to variations in electrode swell and position in real-time. This dynamic adjustment capability allows the system to maintain precision even when electrodes travel longer distances through the manufacturing line.
3Manufacturing precision
If automated positioning systems are implemented to reduce meandering, then positioning accuracy is improved, but manufacturing time increases due to additional detection and correction processes
Solution Approach 1:
The vision sensor performs position detection in advance during the transfer process, before stacking occurs. By capturing images and calculating coordinates during electrode movement rather than after positioning, the system eliminates separate detection and correction steps. This preliminary action integrates measurement and positioning into a single efficient operation.
Solution Approach 2:
The vision sensor system is integrated with the transfer and stacking units, combining detection, processing, and positioning functions into a unified automated flow. The image capture, coordinate processing, and position adjustment occur as a continuous sequence without interrupting the manufacturing rhythm, thereby maintaining high speed while achieving precise positioning.
4Manufacturing precision
If vision sensors and correction mechanisms are added to the manufacturing apparatus, then meandering is reduced, but device complexity increases
Solution Approach 1:
The vision sensor system serves multiple functions: it detects electrode positions, calculates coordinates, guides stacking operations, and provides feedback for continuous adjustment. This multi-functional approach consolidates what could be multiple separate systems into a single integrated unit, reducing overall complexity while achieving high positioning accuracy.
Solution Approach 2:
The system performs self-positioning through automated vision-based detection and adjustment. The vision sensor independently identifies electrode locations, calculates required corrections, and guides the stacking mechanism without requiring external intervention or complex manual alignment procedures. This self-service capability simplifies the overall system architecture.
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 solution improves positioning accuracy, reduces manufacturing time, and enhances the quality of electrode assemblies by correcting meandering issues and maintaining consistent electrode positioning.
Implementation Method 1
bonding the stacked first electrode to the first separator by applying heat and pressure
Implementation Method 2
bonding the stacked first electrode to the first separator by applying heat and pressure
Data Source
AI summary
A method for manufacturing an electrode assembly includes a first combination step of combining a first electrode with an upper portion of a first separator to form a first combination, and a second combination step of combining the first combination so that a second electrode faces the first electrode with the first separator therebetween after the second electrode is stacked on a second separator, wherein the first combination step comprises a first electrode cutting process of moving the first electrode in an X-axis direction that is a progress direction to cut the first electrode to a predetermined size, a first electrode transfer process of transferring the cut first electrode, a first first-electrode position detection process of measuring a Y-axis position of the first electrode, a first separator meandering correction process of moving the first separator, a first stacking process of stacking the first electrode on the first separator.