Cylindrical Battery Manufacture Line

1. Equipment Overview

The Cylindrical Battery Manufacturing Line is a fully automated production system designed for efficient and precise fabrication of cylindrical batteries. The line integrates material preparation, assembly, and quality assurance processes to deliver high-performance cells.

2. Key Processes and Modules

2.1 Winding Material Feed

Application: Automatic feeding and alignment of electrode and separator materials for cell winding.

Specifications:

Material Width: 40–80 mm.

Material Thickness:

Electrode: 0.04–0.1 mm.

Separator: 0.01–0.03 mm.

Tension Control: Servo-based, ±5% deviation.

Feeding Speed: Up to 5 m/min.

2.2 Flattening and Adhesive Application

Application: Ensures precise layering and adhesive application for consistent winding quality.

Specifications:

Flattening Tolerance: ±0.02 mm.

Adhesive Application Width: 1–10 mm.

Adhesive Precision: ±0.1 mm.

Cycle Time: ≤2 seconds per layer.

2.3 Hypot (High Potential) Testing

Application: Verifies insulation and safety standards of wound cells.

Specifications:

Voltage Range: 500–3000 V DC.

Leakage Current Threshold: ≤1 μA.

Testing Speed: ≤3 seconds per cell.

Pass/Fail Criteria: Customizable through PLC.

2.4 Battery Cell Case Insertion

Application: Automated insertion of the wound cell into the cylindrical case.

Specifications:

Case Dimensions:

Diameter: 10–30 mm.

Height: 30–80 mm.

Cycle Time: ≤5 seconds per unit.

Positioning Accuracy: ±0.05 mm.

2.5 Positive Current Collector Laser Welding

Application: Attaches the positive electrode to the battery cap with high-precision laser welding.

Specifications:

Laser Power: 300–500 W.

Wavelength: 1064 nm.

Weld Spot Diameter: 0.1–0.3 mm.

Welding Speed: ≤5 seconds per weld.

Material Compatibility: Nickel, copper, aluminum.

2.6 Negative Current Collector Laser Welding

Application: Attaches the negative electrode to the battery can with laser welding.

Specifications:

Laser Power: 300–500 W.

Wavelength: 1064 nm.

Weld Spot Diameter: 0.1–0.3 mm.

Welding Speed: ≤5 seconds per weld.

Material Compatibility: Nickel, copper, aluminum.

3. Production Line Specifications

Overall Dimensions:

Length: 20,000 mm.

Width: 5,000 mm.

Height: 2,500 mm.

Weight: Approximately 10,000 kg.

Cycle Time: 15–20 seconds per cell (process-dependent).

Production Capacity: Up to 2000 cells/hour.

Automation Level: Fully automated with robotic handling.

4. Vision and Quality Inspection Systems

Pre-Welding Alignment:

High-resolution CCD cameras ensure ±0.02 mm positioning accuracy.

Post-Weld Inspection:

Surface continuity and defect detection via AI-based algorithms.

Adhesive Application Check:

Vision-guided inspection with adjustable thresholds.

Data Logging:

Process results saved to a central server in CSV format.

5. Control and Interface

Control System: Centralized PLC with distributed modular controllers for each station.

HMI:

15-inch touchscreen with multilingual support.

Real-time process monitoring and troubleshooting.

IoT Connectivity:

Remote diagnostics and software updates via Ethernet or cloud.

6. Safety Features

Enclosures: Fully enclosed stations with interlocks.

Emergency Stops: Strategically placed across the line.

Laser Safety: Class 1 laser protection with certified viewing windows.

Overload Protection: Integrated sensors to detect motor or component stress.

7. Electrical Specifications

Power Supply: AC 380V ± 10%, 50/60 Hz, 3-phase.

Maximum Power Consumption: 50 kW.

Control Voltage: 24V DC for auxiliary systems.

8. Cooling System

Type: Water cooling system for laser and electronic components.

Cooling Capacity: 20 kW.

Flow Rate: 10–20 L/min.

9. Environmental Requirements

Operating Environment:

Temperature: 15–30°C.

Humidity: ≤60% RH (non-condensing).

Noise Level: ≤70 dB during operation.

Installation Space: Minimum clearance of 1,500 mm around the line.

10. Maintenance and Warranty

Maintenance Schedule:

Weekly: Inspect lenses, alignment systems, and sensors.

Monthly: Calibrate laser systems and check adhesive applicators.

Quarterly: Full diagnostics of mechanical and electrical systems.

Warranty Period:

Standard: 12 months.

Extended: Up to 36 months available upon request.