Punch-Die Clearance Imaging for Precision Electrode Shearing
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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 uneven shear sections and increased production of defective products.
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 during the repetitive shearing process.
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 and cannot accurately detect the 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 processes these images to calculate precise clearance values. This optical substitution enables measurement of very small clearances (e.g., 10 μm metal substrate thickness) that conventional mechanical equipment cannot detect accurately.
Solution Approach 2:
The patent creates an optical copy (image) of the clearance space between the punch and die using an image sensor. Instead of directly measuring the physical clearance with mechanical probes, the system captures a visual representation of the clearance and processes this image data to determine the actual clearance value. This copying approach enables non-contact, high-precision measurement of the clearance gap.
2Reliability
If the clearance is set at the beginning of operation, then the initial clearance can be established, but the clearance cannot be detected during the repetitive shearing process and may change slightly
Solution Approach 1:
The patent implements a feedback mechanism where the image sensor continuously or periodically captures images of the clearance during the repetitive shearing process. The controller processes these images to detect any changes in clearance from the initial setting. This real-time feedback enables detection of slight clearance changes that occur during operation, allowing for maintenance of consistent product quality without interrupting the shearing process.
3Manufacturing precision
If the clearance is processed to a very low value to shear the electrode without burrs, then the shear quality is improved, but the clearance becomes difficult to measure with conventional equipment
Solution Approach 1:
The patent replaces mechanical measurement methods with optical imaging to measure the very small clearance values (corresponding to 10 μm metal substrate thickness) required for burr-free shearing. The image sensor captures the clearance space optically, and the controller processes these images to calculate precise clearance values, enabling measurement of clearances that are too small for conventional mechanical probes to detect accurately.
Solution Approach 2:
The patent transitions from one-dimensional mechanical probe measurement to two-dimensional optical image capture for measuring the clearance. By capturing the clearance as an image and processing it digitally, the system can measure very small dimensional values with high precision, converting a difficult one-point measurement into a comprehensive area-based measurement that enhances detection capability.
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 precise measurement and monitoring of the clearance, reducing the production of defective products and improving the durability of the electrode mold by detecting and correcting slight changes in clearance.
Implementation Method 1
an image sensor (151) configured to photograph a space between the punch (112) and the die (113)
Implementation Method 2
a light source on the frame, and configured to irradiate light between the die and the punch
Data Source
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AI summary
The present disclosure refers to a clearance-measuring apparatus including an image sensor, 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.