Automated Coiling Device for Jelly Roll Battery Assembly
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Solution Overview
Problem
The challenge in battery assembly lies in achieving compact, reliable, and efficient coiling of jelly roll electrode assemblies without damaging the components during the coiling process, which is complicated by the need for precise tension control and the risk of deformation or tearing.
Innovation Solution
An automated coiling device that includes a winding apparatus, upper and lower spools, a platform to hold a base and shuttle supporting a battery mandrel, with a feedback loop for tension control, allowing for controlled and consistent tension during the coiling of positive and negative electrodes around the mandrel, and a method involving a ligature to secure the mandrel and electrodes, ensuring precise assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the jelly roll is wrapped tightly to eliminate dead space and maximize battery capacity, then the battery achieves compact size and high power output, but the risk of damaging the jelly roll during assembly increases due to the small size of component parts
Solution Approach 1:
A mandrel is introduced as an intermediary tool during the assembly process. The mandrel serves as a temporary support structure that enables tight wrapping of the jelly roll components while protecting them from damage. After assembly, the mandrel is removed, leaving the compact battery structure intact.
Solution Approach 2:
The mandrel is prepared and positioned in advance before the electrode and separator materials are wrapped around it. This preliminary setup ensures that the components are held in the correct positions and tensions are maintained during the wrapping process, preventing damage while achieving compact dimensions.
2Reliability
If the jelly roll is wrapped loosely to avoid damaging the core during mandrel removal, then the risk of damage is reduced, but space is wasted and battery capacity and power decrease due to size constraints
Solution Approach 1:
The mandrel acts as a protective intermediary that allows the jelly roll to be wrapped tightly without directly transferring damaging forces to the core during removal. The mandrel absorbs and distributes the stresses, enabling both tight wrapping and safe removal.
Solution Approach 2:
The design changes the mechanical properties and dimensions of the mandrel to optimize the wrapping process. By adjusting the mandrel's size, material properties, and removal mechanism, the system achieves both tight wrapping for high capacity and safe removal to prevent damage.
3Productivity
If automated coiling is implemented to improve assembly efficiency and productivity, then the production speed increases, but the device complexity and tension control requirements increase
Solution Approach 1:
The automated coiling device incorporates feedback mechanisms that monitor tension during the wrapping process. Sensors detect tension variations and provide real-time information to the control system, which adjusts the wrapping parameters to maintain optimal tension and prevent damage while maximizing productivity.
Solution Approach 2:
The coiling device uses dynamic control mechanisms that can adjust wrapping tension, speed, and other parameters during the assembly process. This dynamic adaptability allows the system to handle variations in material properties and maintain consistent quality while operating at high speeds.
Data Source
AI summary
A system for the automated coiling of a jelly roll electrode assembly for controlled assembly and tensioning of jelly roll assembly is provided. The system includes: a shuttle, and a mandrel to which electrodes are welded; a base, mateable with the shuttle and on which the battery head assembly is mounted for welding to the mandrel; and a coiling device. The coiling device has an upper spool, a lower spool, holding a separator strip and a platform between the two holding the base. The separator strip is threaded through a passage in the mandrel separating positive and negative portions. Rotating the mandrel coils the positive electrode, the separator strip and the negative electrode to coil around the mandrel. The coiling device may include a feedback loop braking one or both spools and allowing the coiling tension to be programmed to a desired level.