Separator Roll Transfer and Alignment for Continuous Unwinding
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Solution Overview
Problem
The manual replacement of separator rolls during the manufacturing of jelly roll-type electrode assemblies disrupts the continuous operation, leading to inefficiencies and material handling issues.
Innovation Solution
An automatic separator supply apparatus is designed to automatically supply a separator winding roll by using a transfer unit to move the roll and an unwinder to unwind the separator, ensuring continuous operation without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual replacement of separator roll is used, then device complexity is reduced, but productivity decreases due to operation stoppage
Solution Approach 1:
The automatic separator supply system is divided into distinct functional modules: a transfer unit with a unit shaft for receiving and moving separator winding rolls, and an unwinder with an unwinder shaft for mounting and unwinding separators. This segmentation allows each module to perform its specific function independently, enabling continuous operation while maintaining manageable system complexity through modular design.
Solution Approach 2:
The transfer unit acts as an intermediary component between the separator storage and the unwinder. It receives separator winding rolls, positions them on the unit shaft, and transfers them to the unwinder shaft, thereby mediating the material flow and enabling continuous separator supply without manual intervention.
2Loss of time
If manual replacement of separator roll is used, then ease of operation is maintained, but loss of time increases due to operator stoppage
Solution Approach 1:
The transfer unit performs preliminary actions by receiving separator winding rolls in advance, positioning them on the unit shaft, and preparing them for transfer. This preliminary positioning and alignment work eliminates the need for manual intervention during critical production periods, reducing material replacement time while automating the alignment process.
Solution Approach 2:
The automatic separator supply system performs self-service by autonomously completing the entire separator replacement process. The transfer unit automatically positions rolls and transfers them to the unwinder without requiring operator intervention, thereby eliminating time loss while the system manages its own operational complexity through automated control mechanisms.
3Manufacturing precision
If automatic alignment of shafts is implemented, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The alignment function is segmented into the transfer unit's inherent positioning capability. The transfer unit is designed with a unit shaft that can be precisely positioned and aligned with the unwinder shaft through controlled movement, achieving accurate alignment without requiring a separate complex alignment mechanism. This segmentation integrates alignment functionality into the existing modular structure.
Solution Approach 2:
The transfer unit serves as an intermediary that bridges the gap between separator storage and the unwinder. Its unit shaft acts as a mediating element that can be precisely aligned with the unwinder shaft through controlled transfer movements, thereby achieving accurate shaft alignment while maintaining system modularity and avoiding additional complex alignment mechanisms.
Data Source
AI summary
The present invention relates to an automatic separator supply apparatus. The automatic separator supply apparatus according to an embodiment of the present invention is an apparatus for supplying a separator winding roll, the apparatus including: a transfer unit which includes a unit shaft for receiving the separator winding roll and moves the received separator winding roll; and an unwinder which includes an unwinder shaft, to which the separator winding roll moved by the transfer unit is mounted, and unwinds the separator from the separator winding roll mounted to the unwinder shaft when the electrode and the separator are wound. The transfer unit mounts the separator winding roll to the unwinder shaft of the unwinder after the unit shaft is aligned with the unwinder shaft of the unwinder.