Z-Fold Prismatic Battery Stacking With Tandem End Effectors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional z-fold prismatic battery interleave stacker machines are limited by low throughput due to repeating place/clamp/fold sequences and synchronization challenges between transfer devices and separator feed systems, which reduce efficiency.
Innovation Solution
A z-fold prismatic battery interleave stacker machine employing counter-rotating tandem end effectors with cam drives and pneumatic ports for efficient handling and interleaving of anode and cathode electrodes, eliminating the need for clamping and enabling dynamic folding of separators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional pick-and-place devices with repeating place/clamp/fold sequences are used, then electrode stacking can be achieved, but throughput is limited due to sequential operations
Solution Approach 1:
The system divides the stacking operation into two independent parallel lines: one line handles anode electrodes with vacuum transfer means, while the other line handles cathode electrodes with vacuum transfer means. Each line operates independently to place electrodes simultaneously on the separator, eliminating the sequential place/clamp/fold cycles of conventional single-line systems and doubling the throughput capability.
Solution Approach 2:
The patent combines multiple functions into integrated vacuum transfer means that simultaneously perform picking, transferring, and placing operations for both anode and cathode electrodes in parallel. The centrally located elevator stack integrates separator feeding with the dual-line electrode placement system, allowing synchronized operation of all components to achieve high-speed stacking without sequential delays.
2Productivity
If multiple transfer devices are used for each electrode type, then electrode handling is possible, but synchronization between transfer devices and separator feed becomes challenging
Solution Approach 1:
The centrally located elevator stack acts as a synchronization hub that receives signals from both vacuum transfer means and coordinates separator feeding accordingly. The system monitors the position and operation status of anode and cathode transfer devices, adjusting separator feed timing to match the synchronized electrode placement rhythm, ensuring reliable coordination between all moving components at high speeds.
Solution Approach 2:
The separator is pre-positioned and fed from the centrally located elevator stack before electrode placement begins. The vacuum transfer means are pre-coordinated to pick electrodes at precisely timed intervals that match the separator feed rate, allowing the entire stacking operation to proceed in a synchronized manner without mid-process adjustments or delays.
3Productivity
If clamping and retention techniques are used to hold the stack, then electrode stability is maintained, but throughput is reduced due to additional sequential steps
Solution Approach 1:
The vacuum transfer means use pneumatic suction to grasp and hold multiple anode and cathode electrodes simultaneously during transfer and placement operations. The vacuum pressure maintains electrode stability throughout the stacking process without requiring mechanical clamps or retention devices, allowing continuous high-speed operation while preventing electrode displacement or misalignment.
Solution Approach 2:
The system transitions from static clamping mechanisms to dynamic vacuum holding that can be rapidly activated and deactivated. The vacuum pressure is dynamically adjusted during electrode transfer to maintain stability, then quickly released upon placement, enabling continuous stacking without the mechanical intervention and time delays associated with traditional clamping and retention techniques.
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
Significantly increases throughput by allowing simultaneous and synchronized movement of electrodes and separators, reducing the need for sequential clamping and retention techniques, thus enhancing the efficiency of the stacking process.
Implementation Method 1
each end effector having a pneumatic port for applying a vacuum pressure to lift an electrode
Implementation Method 2
each end effector having a pneumatic port for applying a positive pressure to release an electrode
Implementation Method 3
a cam drive to rotate the first set of tandem end effectors
Data Source
AI summary
Disclosed is a z-fold prismatic battery interleave stacker machine. In some embodiments, the machine includes a first vertical elevator stack for providing anode electrodes, a second vertical elevator stack for providing cathode electrodes, a centrally located elevator stack configured to lower a partly assembled z-fold stack during assembly, a first set of tandem end effectors for sequentially handling anode electrodes, and a second set of tandem end effectors for sequentially handling cathode electrodes.