Roll Unwinding Speed Control for Near-Depletion Material Supply
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing systems for supplying roll-type materials in secondary battery manufacturing lack the ability to adjust supply speed based on consumption, leading to potential material waste and damage during the unwinding process.
Innovation Solution
An apparatus and method that includes a rotation speed sensor, controller, and sensors to measure roll thickness and distance, allowing for controlled deceleration of the roll speed based on reference values to manage material supply efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the roll rotation speed is maintained at a constant high speed throughout the unwinding process, then productivity is improved, but material damage and operational disruptions occur when the roll is nearly depleted
Solution Approach 1:
The system dynamically adjusts the roll rotation speed based on real-time monitoring of material consumption. The controller receives signals from sensors that detect when the roll is nearing depletion and automatically reduces the rotation speed accordingly, transitioning from constant high speed to variable speed operation to prevent material damage and ensure continuous operation
Solution Approach 2:
The system implements feedback control by continuously monitoring the roll state through sensors (rotation speed sensor, distance sensors) and using this information to adjust the unwinding speed. The controller receives feedback about the remaining material quantity and modifies the rotation speed in response, creating a closed-loop control system that balances productivity with operational reliability
2Loss of substance
If the roll rotation speed is reduced to prevent material damage, then material waste is minimized, but productivity decreases
Solution Approach 1:
The system maintains high productivity for the majority of the unwinding process by operating at high speed, then dynamically transitions to reduced speed only when necessary (when sensors detect near-depletion). This dynamic adjustment minimizes material waste from damage while maintaining overall productivity, rather than operating at reduced speed throughout the entire process
Solution Approach 2:
The system operates in periodic phases: high-speed unwinding phase for most of the material consumption, followed by a low-speed phase when the roll is nearly depleted. This periodic variation in operation speed allows the system to maximize productivity during the productive phase while minimizing material waste during the terminal phase
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
Proposed is an apparatus for supplying a roll-type material, the apparatus including an unwinder for unwinding a roll on which a material is wound, a rotation speed sensor for measuring a rotation speed of the roll, and a controller for performing a first deceleration for decelerating the rotation speed of the roll when the rotation speed of the roll is equal to or greater than a first reference rotation speed, and performing a second deceleration for decelerating the rotation speed of the roll when the rotation speed of the roll is equal to or greater than a second reference rotation speed after the rotation speed of the roll is decelerated. Accordingly, it is possible to adjust a supply speed of the material according to a remaining amount of the material without operator's control, and minimize waste of the material.