Guide Roller Wire Transfer for Uniform Foil Tension
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Solution Overview
Problem
During the foil transfer process for manufacturing battery cells, the foil often breaks due to external impacts or uneven tension, leading to safety risks and reduced operational convenience.
Innovation Solution
A wire transfer device is designed to provide consistent and appropriate tension to the foil, featuring a frame, bobbin, holder, and guide roller with a specific groove and protruding regions to manage the foil's movement and tension.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual movement of broken foil is performed by operator, then foil can be repositioned to restart operation, but tension delivered to foil becomes non-uniform and safety risks increase
Solution Approach 1:
The system uses a sensor to detect foil breakage and automatically controls the wire drive mechanism to retract and rewind the wire, enabling the system to handle foil breakage without manual intervention. This eliminates the need for operators to manually reposition foil while maintaining uniform tension through automated control.
Solution Approach 2:
The patent replaces manual mechanical operations with an automated sensor-based detection and control system. The sensor detects foil breakage and triggers a control mechanism that automatically adjusts the wire tension and repositioning, substituting human mechanical handling with an automated electromechanical system.
2Reliability
If wire tension is increased to prevent foil breakage, then foil handling reliability improves, but wire breakage risk increases
Solution Approach 1:
The system dynamically adjusts wire tension based on real-time detection of foil breakage. The sensor monitors the system state and the control mechanism adjusts wire tension accordingly, using higher tension only when needed to retract broken foil segments and maintaining lower tension during normal operation to prevent wire breakage.
Solution Approach 2:
The patent changes the tension parameter dynamically based on system state. During normal operation, tension is maintained at a lower level to protect the wire. Upon detecting foil breakage, the system increases tension temporarily to retract the foil, then reduces tension again, thus protecting both the foil and wire from damage.
Data Source
AI summary
A wire transfer device is provided. The wire transfer device includes a frame, a bobbin connected to the frame and on which a wire is configured to be wound; a holder including a first end connected to the wire and a second end opposite to the first end and configured to be connected to foil; and a guide roller configured to guide a movement path of the wire or the holder. The guide roller includes a groove region for accommodating the wire and a protruding region extending from the groove region and configured to contact with the holder.