Stacked Cell Separator Tension Control via Feedback
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Solution Overview
Problem
The existing stacked cell manufacturing device faces instability in separator tension, leading to varying stack quality due to characteristics of the separator, which affects the accuracy and reliability of the stacked cell production.
Innovation Solution
A stacked cell manufacturing device that alternately disposes negative and positive electrode plates in the valley fold parts of a bellows-shaped folded separator, incorporating a tension measuring unit and a control unit to adjust the separator tension within a certain range, ensuring high-accuracy stacking through conveyance path adjustments and learning mode operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the separator is conveyed using a reciprocating transfer head structure, then the stacking process can be completed, but the separator tension varies and stack stability deteriorates
Solution Approach 1:
The patent implements a feedback control system where a tension detection unit continuously monitors separator tension during conveyance, and the control unit adjusts conveyance parameters based on this feedback to maintain tension within a predetermined range, thereby resolving the contradiction between achieving stacking completion and maintaining tension consistency
Solution Approach 2:
The patent changes the conveyance parameter (tension) from uncontrolled to controlled by establishing a predetermined tension range and using the tension detection unit to monitor and adjust the separator tension during the stacking process, improving both reliability and stability
2Manufacturing precision
If the separator tension is not controlled, then the manufacturing process is simple, but the manufacturing precision of stacked cells deteriorates
Solution Approach 1:
The control unit receives tension detection results and automatically adjusts conveyance parameters to maintain tension within the predetermined range, achieving precise tension control without requiring complex manual intervention or overly complicated control systems
Solution Approach 2:
The system performs self-adjustment of separator tension through the feedback loop, where the control unit automatically modifies conveyance conditions based on real-time tension measurements, eliminating the need for external manual control and reducing operational complexity
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
This approach stabilizes the production of high-quality stacked cells by maintaining consistent separator tension, reducing individual variations and manufacturing inaccuracies, and adapting to changes in separator characteristics over time.
Implementation Method 1
a tension measuring unit arranged to measure tension of the separator conveyed inside and to send the measurement result to the control unit
Data Source
AI summary
In the stacking process to stack negative electrode plates and positive electrode plates alternately with a bellows-shaped separator therebetween, a control unit performs tension control to change control condition to determine operations of a conveyance adjustment unit so that tension of the separator is within a certain range.