Multi-Packaging Battery Line Layout for Downtime-Free Cell Transfer
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Solution Overview
Problem
The existing secondary battery manufacturing facilities face significant productivity losses due to frequent stoppages required for component replacement and material supply in the tab welding and packaging units, leading to prolonged downtime and reduced manufacturing efficiency.
Innovation Solution
Implementing a multi-line method with a multipackaging unit system that includes an electrode supply unit, a tab welding unit, a packaging unit, a temporary buffer, and a transfer unit, allowing continuous discharge or supply of electrode assemblies even when the tab welding or packaging unit is stopped, utilizing an automatic guided vehicle or autonomous mobile robot for seamless transfer between units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If an in-line manufacturing method is used with sequential units, then the manufacturing process is simple and compact, but the production line must be stopped for component replacement and material supply, reducing productivity
Solution Approach 1:
The manufacturing system is divided into multiple independent parallel lines, each capable of autonomous operation. This segmentation allows one line to be stopped for maintenance while others continue production, eliminating the bottleneck effect in sequential in-line systems and maintaining overall productivity.
Solution Approach 2:
Multiple parallel manufacturing lines enable continuous production by allowing switching between lines during maintenance. When one line stops for component replacement or material supply, other lines continue operating, ensuring the useful action of manufacturing continues without interruption to overall output.
2Reliability
If component replacement and material supply are performed twice a day in the tab welding unit and packaging unit, then maintenance and material replenishment are ensured, but the manufacturing facility must be stopped during these periods, causing serious decrease in productivity
Solution Approach 1:
Each parallel manufacturing line is equipped with its own dedicated components and materials, allowing independent maintenance and material supply operations. This local autonomy ensures that maintenance activities in one line do not affect the operational status of other lines, maintaining overall system reliability while preserving productivity.
Solution Approach 2:
Components and materials are prepared and staged in advance for each parallel line, enabling quick replacement and replenishment operations. This preliminary preparation reduces the duration of maintenance stops and allows for faster turnaround between production cycles.
3Device complexity
If a single packaging unit is used, then the system structure is simple, but the entire production line stops when the packaging unit requires maintenance or material supply
Solution Approach 1:
The packaging function is segmented into multiple independent packaging units operating in parallel. Each unit can be maintained or replenished independently without affecting the others, allowing maintenance activities to be performed on one unit while production continues on other units, thus maintaining productivity while managing system complexity through modular design.
4Ease of repair
If the tab welding unit stops for component replacement, then welding maintenance can be performed, but the electrode supply unit and packaging unit must also stop, causing cascading production loss
Solution Approach 1:
The manufacturing system is segmented into independent parallel lines with separate welding units. This allows the welding unit in one line to be maintained or repaired without affecting the operation of welding units in other lines. The electrode supply unit and packaging unit in other lines continue operating independently, preventing cascading stoppages and maintaining overall productivity.
Data Source
AI summary
The present disclosure relates to a secondary battery manufacturing system in which a packaging unit of a secondary battery manufacturing facility are configured to have multiple packaging units, and having a multipackaging unit such that a transfer box in which an electrode assembly is seated is transferred to each of the packaging units by a transfer unit, and including an electrode supply unit having a plurality of stacking devices supplying an electrode assembly in which a plurality of battery cells are stacked, a tab welding unit, at least one packaging unit, at least one temporary buffer, and a transfer unit.