Floatation Roll Yaw Control for Foil Meandering Correction
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Solution Overview
Problem
Existing methods for correcting meandering in floatation conveyance of lithium metal foils, such as tilting the floatation roll, create uneven loads that can twist and tear the foil.
Innovation Solution
A conveyer apparatus with a floatation roll that supports the foil contactlessly, using a cylindrical shape and air flow, and rotates in a yaw direction to set different wrap angles on the entry and exit sides for meandering correction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If meandering correction is performed by tilting the floatation roll in the width direction, then meandering of the work is corrected, but the work is twisted and easily torn in the width direction due to uneven loads
Solution Approach 1:
The invention changes the correction mechanism from tilting the roll in the width direction (horizontal plane) to rotating the roll in the yaw direction (vertical plane). This dimensional change allows meandering correction to be achieved by creating a wrap angle difference between entry and exit sides, which generates a restoring moment without applying uneven lateral loads that would twist or tear the work.
Solution Approach 2:
The invention changes the operational parameter from roll tilt angle to wrap angle distribution. By controlling the wrap angles on the entry side (αin) and exit side (αo) to be different, the system creates an asymmetric support condition that generates a corrective moment. This parameter change allows meandering correction while maintaining uniform load distribution across the work width, preventing twisting and tearing.
2Force
If contactless floatation conveyance is used, then contact resistance is eliminated and low-tension conveyance is enabled, but meandering of the work is likely to occur
Solution Approach 1:
The invention implements a feedback control system where sensors detect the position of the work and the control unit adjusts the roll rotation in the yaw direction based on detected meandering. This closed-loop feedback allows the system to maintain contactless floatation conveyance (zero contact resistance) while actively correcting meandering occurrences in real-time, thus resolving the contradiction between contactless operation and work stability.
3Ease of manufacture
If lithium foil is conveyed in floatation conveyance, then film bonding and peeling processes are eliminated, but meandering is likely to occur due to the light weight of lithium metal
Solution Approach 1:
The invention enables the floatation roll to self-correct meandering through automatic rotation in the yaw direction based on detected work position. This self-service mechanism maintains the simplicity of the floatation conveyance process (no film bonding required) while actively compensating for meandering caused by the light weight of lithium foil, thus resolving the contradiction between process simplicity and work stability.
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
This method minimizes the risk of breaking the foil during conveyance by applying balanced pressures to correct meandering without excessive load.
Implementation Method 1
contactless floatation conveyance is known to be free from contact resistance and enables low-tension conveyance
Implementation Method 2
a wrap angle on an entry side with respect to an apex point and a wrap angle on an exit side with respect to the apex point are set to be different
Data Source
Figure 1~2
Figure 3
Figure 4A~4C
AI summary
A floatation roll (20a) supports a work (W) to be conveyed contactlessly using a force applied to the work (W) contactlessly. The floatation roll (20a) has a cylindrical shape extending in a direction of width (B) of the work (W), and at least a surface of the floatation roll (20a) facing the work (W) being formed by a circumferential surface. A driving unit (20f) rotates the floatation roll (20a) in a yaw direction. Of a wrap angle of the work supported by the floatation roll contactlessly, a wrap angle on an entry side with respect to an apex point and a wrap angle on an exit side with respect to the apex point are set to be different.