Layer Turner Stacking for Fast, Precise Battery Cell Assembly
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Solution Overview
Problem
Existing manufacturing processes for fuel or battery cells face inefficiencies and precision issues due to separator film tearing during stacking, leading to inconsistent quality and increased costs.
Innovation Solution
A conveyor system with layer turners that radially retract and extend pick-ups to minimize distance between delivery locations, combined with a stacking table that moves back and forth, allowing precise stacking of anode and cathode layers with high speed and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the separator film is pulled taut during stacking, then the stacking process can proceed, but the separator film may tear leading to inconsistent quality
Solution Approach 1:
The holding elements are designed to dynamically adjust their position between a retracted position and a holding position. This dynamic adjustment allows the system to apply holding force only when needed during stacking, preventing separator film tearing while maintaining stacking productivity
Solution Approach 2:
The holding elements are positioned in advance at the four corners of the electrode foil or separating foil before the stacking operation. This preliminary positioning ensures that the separator film is secured before pulling taut, preventing tearing during the stacking process
2Productivity
If the pick-ups are positioned close together to minimize travel distance, then deposition speed increases, but collision risk between pick-ups increases
Solution Approach 1:
The pick-ups are designed with radial retraction capability, allowing them to dynamically adjust their position. When approaching the space between layer turners, the pick-ups retract radially to avoid collision, enabling closer positioning of layer turners while maintaining safety
Solution Approach 2:
The second drive radially retracts the pick-up in advance before it approaches the space between the layer turners. This preliminary anti-action prevents collision from occurring in the first place, allowing the system to operate with minimal travel distance
3Device complexity
If the pick-ups follow a circular trajectory, then the stacking path is simple, but the distance between delivery locations increases reducing efficiency
Solution Approach 1:
The pick-up trajectory is changed from a simple circular path to an elliptical path with radial retraction. This dynamic trajectory optimization reduces the distance between delivery locations at the 6 o'clock position while maintaining trajectory simplicity through controlled radial movement
Solution Approach 2:
The trajectory parameters are changed by introducing radial retraction movement to the circular path. This creates an elliptical trajectory that optimizes the distance between delivery locations while keeping the overall path structure simple and controllable
Data Source
AI summary
A method and an apparatus for the production of modules or precursors of modules, in particular of fuel or battery cells containing layer material. The method includes conveying individual anode layers to a first transfer location for transfer to a first layer turner; conveying individual cathode layers to a second transfer location for transfer to a second layer turner; turning picked-up anode or cathode layers by a respective angle of rotation to a respective first or second delivery location; reciprocating the anode or cathode layers by a respective angle of rotation to a respective first or second delivery location; and transferring the anode or cathode layers to respective first or second layer turners at the respective first and second delivery locations.