Battery Separator Roll Changeover With Vacuum End Splicing
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Solution Overview
Problem
The manual replacement of bobbins and connection of electrode separator ends in lithium ion battery manufacturing is labor-intensive, time-consuming, and prone to safety accidents, leading to decreased productivity and manufacturing quality due to frequent roll replacements and disconnections.
Innovation Solution
A secondary battery electrode film and separator supply device that automatically replaces empty bobbins with new ones using a 180-degree rotating bobbin mount and extracts/ reconnects electrode separator ends via vacuum suction, with integrated units for feeding, cutting, and taping to maintain continuous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual replacement of bobbins is performed, then workers can replace empty bobbins with new ones, but productivity decreases due to frequent stoppages and labor-intensive operations
Solution Approach 1:
The system performs automatic bobbin replacement through self-service mechanisms including automated bobbin extraction from the spool, automatic bobbin mounting on the shaft, and automated end-to-end connection of electrode separators, eliminating the need for manual worker intervention and continuous facility stoppages
Solution Approach 2:
Manual mechanical operations are replaced with an automated mechanical system comprising a bobbin extractor, bobbin mounter, and connection device that automatically perform bobbin replacement and separator connection, substituting human labor with mechanized automation
2Ease of operation
If manual replacement of heavy rolls is performed, then workers can handle bobbin replacement, but safety accidents frequently occur
Solution Approach 1:
The system handles heavy bobbins through self-service automated mechanisms that extract, transport, and mount bobbins without human physical contact, eliminating safety hazards associated with manual handling of heavy rolls while maintaining ease of operation through automated control
3Reliability
If manual connection of electrode separator ends is performed, then workers can connect separators, but manufacturing quality deteriorates due to frequent disconnections
Solution Approach 1:
The system merges the bobbin replacement function with the electrode separator connection function into an integrated automated device, where the connection device automatically connects separator ends during the bobbin replacement process, ensuring manufacturing quality without requiring separate manual operations
Solution Approach 2:
Manual connection operations are replaced with an automated connection device that precisely aligns and connects electrode separator ends, eliminating variability and quality deterioration associated with manual disconnections while managing device complexity through automation
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
Enables automated replacement and connection of bobbins and electrode separator ends, reducing manual labor, minimizing safety risks, and enhancing productivity by maintaining continuous operation without disconnections.
Implementation Method 1
automatically extracting an end of a wound electrode separator through vacuum suction
Data Source
AI summary
A secondary battery electrode film and separator supply device configured to: replace a bobbin when an electrode separator is used up by automatically extracting an empty bobbin from a spool, mounting the empty bobbin on a side of a bobbin mount of a bobbin changer, changing the position of a new bobbin mounted on another side by rotating the bobbin mount 180 degrees, and then moving and mounting the new bobbin on the spool; automatically extracting an end of a wound electrode separator through vacuum suction and connecting the end to another electrode separator; and feed a replacing material roll to a moving spool, cut a finishing tap at an end of a material by a predetermined length, and then automatically connect a new separator end of the replacing material roll and an in-use separator end through taping.