Stepped Clearance Jig for Punch-Die Gap Measurement
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Solution Overview
Problem
Conventional measurement equipment cannot accurately measure and quantify the clearance between the punch and die in shearing molds for secondary battery electrode plates, leading to irregular shearing surfaces, burrs, and reduced mold lifespan due to imprecise clearance settings.
Innovation Solution
A standard jig and apparatus using a first block with stepped portions of varying clearance widths, coupled with a second block for adjustable overlap, combined with a light source, camera, and controller for precise measurement and evaluation of clearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional measurement equipment is used to measure clearance between punch and die, then measurement capability is limited, but measurement precision is insufficient for very small clearance values
Solution Approach 1:
A standard jig with known clearance values is introduced as an intermediary reference object. The jig includes multiple blocks with precisely manufactured clearance gaps that serve as calibration standards, enabling indirect measurement of the actual clearance between punch and die through comparison rather than direct measurement.
Solution Approach 2:
The invention creates optical copies and images of the clearance gaps using a camera system. By photographing the clearance spaces and analyzing the images, the system transforms physical clearance measurements into digital image analysis, allowing precise measurement of very small gaps through pixel analysis and image processing techniques.
2Manufacturing precision
If clearance is set to very small value to prevent burr formation, then electrode quality improves, but measurement capability of conventional equipment becomes insufficient
Solution Approach 1:
The standard jig with precisely known clearance values is prepared in advance as a reference standard. By establishing known reference clearances before measurement, the system creates a baseline for comparison that enables accurate determination of unknown clearance values through image analysis and pattern matching techniques.
Solution Approach 2:
The invention transforms the measurement parameter from direct physical clearance measurement to optical image analysis. By changing the measurement approach from mechanical contact methods to non-contact optical imaging and pixel-based analysis, the system achieves the capability to measure very small clearance values that were previously unmeasurable.
3Duration of action of stationary object
If clearance measurement is not performed accurately, then mold lifespan is reduced due to irregular shearing, but implementing measurement requires specialized equipment and methods
Solution Approach 1:
The standard jig serves multiple functions: it acts as a reference standard for calibration, a measurement tool for clearance determination, and a teaching aid for establishing measurement criteria. This multi-functional design reduces the need for separate specialized equipment for each measurement task.
Solution Approach 2:
The measurement system uses itself for calibration and verification through the standard jig. The known clearance values in the jig provide self-reference capability, allowing the system to validate its own measurements and maintain accuracy without requiring external calibration standards or complex reference equipment.
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 quantitative evaluation of clearance, reducing burr formation and improving electrode quality by accurately measuring and adjusting the clearance between the punch and die, thereby enhancing mold durability and reducing defect rates.
Implementation Method 1
a light source configured to radiate light toward a bottom of a standard jig for measuring clearance
Implementation Method 2
a camera configured to photograph the stepped portion of the first block in a state in which the light is radiated by the light source
Data Source
AI summary
A standard jig for measuring clearance includes a first block having a stepped portion including a plurality of steps, each having a different clearance width, and a second block coupled to the first block such that the second block partially overlaps the stepped portion of the first block.