Winding Tension Feedback Control for Short-Width Substrates
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Solution Overview
Problem
Current winding technologies face difficulties in achieving precise tension control during the winding of short-width electrode plates and separators due to low tension levels, leading to defects such as deformation and cracks, as existing sensors are inadequate for real-time tension measurement and control.
Innovation Solution
A winding device equipped with a controller, electric motor, and tension sensor installed on a conveying roller, which dynamically adjusts the winding speed based on real-time tension measurements, using a load cell or strain gauge for precise tension sensing and data conversion to ensure accurate tension control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If existing sensors are used for tension measurement, then the device complexity is reduced, but the measurement precision is insufficient for low tension levels in short-width winding
Solution Approach 1:
The patent replaces conventional mechanical tension sensors with a vision-based measurement system that uses cameras and image processing algorithms to detect and measure tension-induced deformations of the substrate, achieving high-precision tension measurement without complex mechanical sensing components
Solution Approach 2:
The patent introduces an intermediary visual field measurement approach where the tension force is indirectly measured through its effect on the substrate's visual appearance (deformation, stretching), rather than directly measuring the force itself, enabling precise measurement of low tension levels
2Manufacturing precision
If real-time tension control is implemented, then the manufacturing precision is improved, but the device complexity increases due to additional sensors and control systems
Solution Approach 1:
The patent implements a feedback control system where the vision-based tension measurement results are continuously fed back to the winding device controller, which automatically adjusts winding parameters to maintain optimal tension levels, achieving precise real-time control through software-based feedback rather than complex hardware control mechanisms
Solution Approach 2:
The patent replaces complex mechanical tension control mechanisms with a software-based control system that uses vision measurement data to dynamically adjust winding parameters, simplifying the physical control system while achieving precise tension control through intelligent algorithms
3Productivity
If conventional winding technology is used, then the device complexity is low, but the productivity is reduced due to inability to handle short-width substrates with appropriate tension
Solution Approach 1:
The patent creates a universal winding system that can handle both traditional and short-width substrates by integrating vision-based tension measurement and control, making the system multi-functional and adaptable to different substrate types and width requirements without requiring separate specialized 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 real-time precise tension measurement and control, preventing defects like deformation and cracks by synchronizing the winding speed with the desired tension profile, effectively addressing the challenges of short-width tension control in the winding process.
Implementation Method 1
a tension sensor that is installed on a conveying roller that transports the substrate wound around the winding core to precisely sense a tension value of the substrate in real time... The tension sensor may include a load cell or a strain gauge
Data Source
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AI summary
The present disclosure relates to a winding device that includes a controller for determining a winding speed corresponding to a tension profile of a substrate to be wound and for outputting a motor control signal corresponding to the winding speed. The winding device includes an electric motor for rotating a winding core to wind the substrate according to the motor control signal; and a tension sensor that is installed on a conveying roller that transports the substrate wound around the winding core to precisely sense a tension value of the substrate in real time and provide the tension value to the controller. The controller dynamically controls the winding speed of the electric motor by using the tension value.