Strip Cutting Rollers for High-Speed Battery Electrode Winding
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Solution Overview
Problem
Existing apparatuses for producing electrical energy storage devices face challenges with high-speed winding, where linear motors experience extreme accelerations, leading to large dimensions and reduced productivity due to the need for deceleration space and intermittent movement, resulting in increased bulk and cost.
Innovation Solution
A cutting and conveying apparatus with a pair of opposing rollers and a cutting unit that uses a brushless electric motor and motion transmission means to move the rollers, allowing for continuous support and precise cutting of strips, facilitating efficient high-speed winding and reducing the need for extensive deceleration space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a linear motor is used to drive the gripping assembly and cutting assembly at high winding speeds, then the cutting and gripping function is achieved, but the motor dimensions become disproportionately large due to extreme accelerations and deceleration space requirements
Solution Approach 1:
The patent replaces the linear motor system with a rotary motor (spindle) that drives a rotating cutter. This substitution eliminates the need for rapid linear acceleration and deceleration of heavy components, as the rotary system naturally handles high-speed operation without requiring disproportionate motor size. The cutting action is achieved through rotational motion of the cutter blade rather than linear movement of a gripping assembly.
Solution Approach 2:
Instead of moving the cutter and gripping assembly linearly along with the strip (as in conventional systems), the patent inverts the approach by rotating the cutter in place while the strip moves continuously through it. This inversion allows the cutter to remain stationary in position while performing cutting actions, eliminating the need for deceleration space and reducing motor size requirements.
2Ease of manufacture
If the gripping assembly moves linearly with intermittent motion to cut and grip strips, then the cutting function is achieved, but productivity is reduced due to the need for deceleration space and complex reinsertion procedures
Solution Approach 1:
The patent implements continuous cutting action through the rotating cutter that operates without interruption as the strip passes through. The rotary motion allows the cutter to continuously engage and cut the strip at high speed without the need for intermittent stopping, decelerating, and repositioning required by linear gripping assemblies. This continuous action significantly increases productivity.
Solution Approach 2:
The rotating cutter is positioned and oriented in advance to meet the strip in its path, eliminating the need for the gripping assembly to decelerate and then reinsert the strip into the next winding. The cutter is already in position and ready to cut as the strip arrives, allowing seamless continuous operation.
3Reliability
If supports are added on board the gripping assembly to prevent strip bending, then strip support is improved, but the mass of the assembly increases further
Solution Approach 1:
The patent extracts the support function from the moving gripping assembly and provides it through fixed support elements in the machine structure. The strip is supported by stationary guides and rollers in the machine frame rather than by additional components attached to the moving cutter assembly, thereby eliminating the need to increase assembly mass.
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
The apparatus enables efficient cutting and conveying of strips at high speeds, reducing bulk and cost by minimizing the size of the motor and ensuring reliable strip insertion into the next winding, enhancing productivity and reducing the risk of strip damage.
Implementation Method 1
uses a brushless electric motor
Implementation Method 2
motion transmission means to move the rollers
Implementation Method 3
a pair of opposing rollers and a cutting unit that uses a brushless electric motor and motion transmission means to move the rollers
Data Source
Figure 1
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Figure 3
AI summary
A support apparatus (50) for producing electrical energy storage devices comprising a support element (51), which is linearly movable along a feeding plane (FP), an actuator system, which is configured to operate the support element (51) intermittently, a first roller (54), which is configured to be rotatably operated at a variable speed, and a second roller (55), opposite the first roller (54). A further actuator system is configured to control the speed of the first roller (54) by compensating the intermittent movement of the support element (51).