Multi-Roller Battery Can Forming for Continuous Precision Shaping
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Solution Overview
Problem
The existing methods for forming cylindrical secondary battery cans require extensive process time and multiple facilities in parallel, leading to inefficiencies and deviations in setting values during facility transfer, which affect the forming quality.
Innovation Solution
A multi-roller system with independently rotating rollers of different shapes and heights, allowing for simultaneous and sequential processing of battery can formation stages without the need for facility transfer, applying pressure at multiple points to minimize load and ensure precise forming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple forming facilities are installed in parallel to increase production capacity, then productivity is improved, but device complexity and loss of time increase due to facility transfer requirements
Solution Approach 1:
The patent combines multiple forming facilities into a single integrated multi-roller system where different rollers perform CBD, CCR, and CSZ processes sequentially on the same battery can. This eliminates the need to transfer the battery can between separate facilities, thereby maintaining high productivity while removing transfer time losses and reducing device complexity.
2Productivity
If multiple forming facilities are installed in parallel to increase production capacity, then productivity is improved, but manufacturing precision deteriorates due to deviation in setting values during facility transfer
Solution Approach 1:
By integrating multiple forming processes into one unified multi-roller system, the patent ensures that all forming operations are performed on the same battery can without removal or transfer. This eliminates the risk of setting value deviations that occur during facility transfer, thereby maintaining consistent manufacturing precision and forming quality across all processes.
Solution Approach 2:
The multi-roller system is designed as a universal apparatus where a single device performs multiple forming functions (CBD, CCR, CSZ) with different roller configurations. This multi-functionality ensures that all processes are executed within the same system environment, preventing the loss of information and setting value deviations that would occur when transferring between specialized facilities.
3Manufacturing precision
If sequential processes (CBD, CCR, CSZ) are performed to form the battery can, then manufacturing precision is maintained, but loss of time increases due to extended process duration
Solution Approach 1:
The patent implements continuous forming processes where the battery can remains in the multi-roller system throughout all stages (CBD, CCR, CSZ) without interruption or removal. The rollers operate sequentially but continuously on the same workpiece, eliminating idle time between processes and reducing total process time while maintaining manufacturing precision through consistent system conditions.
Solution Approach 2:
By merging multiple sequential forming processes into a single integrated system, the patent eliminates the time required for transferring and re-fixing the battery can between separate facilities. The combined system performs all forming operations in a continuous workflow, significantly reducing total process time while preserving the precision required for each individual process.
4Manufacturing precision
If high load is applied and large process time is used to form the battery can, then manufacturing precision is improved, but productivity deteriorates
Solution Approach 1:
The patent segments the forming process into multiple independent roller units, each responsible for a specific forming stage (CBD, CCR, CSZ). This segmentation allows each roller to apply optimized load and pressure for its specific function while operating in parallel within the same system, reducing the total process time required to achieve high manufacturing precision and thereby improving productivity.
Solution Approach 2:
The integrated multi-roller system enables continuous processing where the battery can moves through different forming stages without interruption. Each roller applies the necessary load and pressure for its specific forming function in a continuous workflow, eliminating the need for repeated setup and transfer operations, thus maintaining high forming quality while significantly improving production rate.
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 approach significantly reduces process time, minimizes deviations, and improves forming quality by unifying processes and applying force efficiently across multiple rollers, thereby enhancing the efficiency and consistency of battery can production.
Implementation Method 1
forming an inclined section in which an end of the opening portion of the battery can is inclined toward a central axis of the battery can by pressing the end of the opening portion
Data Source
AI summary
A multi-roller system includes at least two pairs of rollers, in which the at least two pairs of rollers rotate about independent rotation axes, respectively. Changes in heights of the at least two pairs of rollers are controlled. Cross-sections of the at least two pairs of more of rollers have different shapes. The at least two pairs of rollers approach and press the battery can at intervals between the at least two pairs of rollers.