Wire Transfer Roller Structure for Uniform Foil Tension
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Solution Overview
Problem
During the foil transfer process for manufacturing battery cells, the foil is prone to breaking due to external impacts or uneven tension, leading to safety hazards and reduced operational efficiency.
Innovation Solution
A wire transfer device is designed to provide consistent and appropriate tension to the foil, featuring a frame, bobbin, holder, and guide roller with a specific groove and protruding region configuration, along with a tension adjustment unit and driving device to ensure precise control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual movement of broken foil is performed by operator, then foil can be repositioned to restart operation, but tension delivered to foil becomes non-uniform and safety hazards occur
Solution Approach 1:
The system uses a sensor to detect foil breakage and automatically controls the wire feeding mechanism to rewind and reposition the foil, eliminating the need for manual operator intervention. The motor-driven wire feeding unit automatically adjusts tension and repositions the foil holder, allowing the system to service itself without human involvement.
Solution Approach 2:
The patent replaces manual mechanical manipulation with an automated control system comprising sensors, motors, and control units. The limit sensor detects foil position and breakage, while the motor controls wire feeding and holder repositioning, substituting human mechanical actions with automated electromechanical systems that provide uniform tension and eliminate safety hazards.
2Speed
If external impact or tension is applied to foil during transfer, then foil movement is achieved, but foil breakage occurs
Solution Approach 1:
The system dynamically adjusts wire tension through motor-controlled wire feeding, allowing the foil to be transferred at appropriate speeds without excessive force. The motor can modulate the pulling force in real-time based on sensor feedback, maintaining optimal tension that enables fast transfer while preventing breakage from excessive stress.
Solution Approach 2:
The limit sensor provides feedback on foil position and tension status, allowing the control system to adjust wire feeding speed and tension dynamically. When the sensor detects abnormal tension or foil position, the motor adjusts its output to prevent breakage, creating a closed-loop control system that balances transfer speed with foil integrity.
Data Source
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Figure 2B
AI summary
A wire transfer device (10) is provided. The wire transfer device (10) includes a frame (100), a bobbin (200) connected to the frame (100) and on which a wire (11) is configured to be wound; a holder (700) including a first end (701) connected to the wire (11) and a second end (702) opposite to the first end and configured to be connected to foil (21); and a guide roller (600) configured to guide a movement path of the wire (11) or the holder (700). The guide roller (600) includes a groove region (602) for accommodating the wire (11) and a protruding region (601) extending from the groove region (602) and configured to contact with the holder (700).