Optical Punch-Die Clearance Monitoring for Shear Molds
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Solution Overview
Problem
Conventional measuring equipment is unable to accurately measure the clearance of a precisely processed shear mold used in manufacturing electrode plates for rechargeable batteries, leading to the production of defective products due to undetected changes in clearance during repetitive shearing processes.
Innovation Solution
A clearance-measuring apparatus equipped with an image sensor and a controller that captures images of the space between the punch and die and measures the clearance based on the images, allowing for accurate detection of slight changes in clearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional measuring equipment is used to measure the clearance of the shear mold, then the measurement process is simple, but the measurement precision is insufficient to detect slight changes in clearance
Solution Approach 1:
The patent replaces conventional mechanical measuring equipment with an optical measurement system consisting of an image sensor and controller. The image sensor captures images of the clearance space between punch and die, and the controller measures the clearance based on these images, achieving high measurement precision without mechanical contact that could interfere with the measurement
Solution Approach 2:
The patent creates an optical copy (image) of the clearance space between the punch and die using an image sensor. This optical copy allows for precise measurement of the clearance without physically measuring the actual space, enabling detection of slight changes in clearance through image analysis
2Reliability
If the clearance is set at the beginning of operation, then the initial clearance is established, but the clearance cannot be detected during repetitive shearing process
Solution Approach 1:
The patent implements a feedback system where the image sensor continuously monitors the clearance between punch and die during operation, and the controller processes the captured images to detect changes in clearance. This feedback mechanism allows for real-time detection of clearance variations, enabling timely adjustments to maintain reliable operation
Solution Approach 2:
The patent enables continuous monitoring of the clearance throughout the repetitive shearing process. The image sensor and controller operate continuously to capture and analyze images of the clearance space, ensuring that clearance changes are detected at all times rather than only at initial setup, maintaining reliable measurement throughout operation
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
The apparatus enables real-time monitoring and correction of clearance, reducing the production of defective products and improving the durability of the electrode mold by maintaining precise processing conditions.
Implementation Method 1
an image sensor in a mold including a frame, a punch on the frame and configured to be moved in a vertical direction, and a die on the frame and spaced apart from the punch, the image sensor being configured to capture an image of a space between the punch and the die
Data Source
AI summary
One or more embodiments of the present disclosure provides a clearance-measuring apparatus including an image sensor in a mold including a frame, a punch on the frame and configured to be moved in a vertical direction, and a die on the frame and spaced apart from the punch, the image sensor being configured to capture an image of a space between the punch and the die, and a controller configured to measure a clearance of the punch and the die based on the image.