Key Processes and Modules
1. Winding Material Feed
· Application: Automatic feeding and alignment of electrode and separator materials for cell winding.
· Specifications:
o Material Width: 40–80 mm.
o Material Thickness:
■ Electrode: 0.04–0.1 mm.
■ Separator: 0.01–0.03 mm.
o Tension Control: Servo-based, ±5% deviation.
o Feeding Speed: Up to 5 m/min.
2. Flattening and Adhesive Application
· Application: Ensures precise layering and adhesive application for consistent winding quality.
· Specifications:
o Flattening Tolerance: ±0.02 mm.
o Adhesive Application Width: 1–10 mm.
o Adhesive Precision: ±0.1 mm.
o Cycle Time: ≤2 seconds per layer.
3. Hypot (High Potential) Testing
· Application: Verifies insulation and safety standards of wound cells.
· Specifications:
o Voltage Range: 500–3000 V DC.
o Leakage Current Threshold: ≤1 μA.
o Testing Speed: ≤3 seconds per cell.
o Pass/Fail Criteria: Customizable through PLC.
4. Battery Cell Case Insertion
· Application: Automated insertion of the wound cell into the cylindrical case.
· Specifications:
o Case Dimensions:
■ Diameter: 10–30 mm.
■ Height: 30–80 mm.
o Cycle Time: ≤5 seconds per unit.
o Positioning Accuracy: ±0.05 mm.
5. Positive Current Collector Laser Welding
· Application: Attaches the positive electrode to the battery cap with high-precision laser welding.
· Specifications:
o Laser Power: 300–500 W.
o Wavelength: 1064 nm.
o Weld Spot Diameter: 0.1–0.3 mm.
o Welding Speed: ≤5 seconds per weld.
o Material Compatibility: Nickel, copper, aluminum.
6. Negative Current Collector Laser Welding
· Application: Attaches the negative electrode to the battery can with laser welding.
· Specifications:
o Laser Power: 300–500 W.
o Wavelength: 1064 nm.
o Weld Spot Diameter: 0.1–0.3 mm.
o Welding Speed: ≤5 seconds per weld.
o Material Compatibility: Nickel, copper, aluminum.
Production Line Specifications
· Overall Dimensions:
o Length: 20,000 mm.
o Width: 5,000 mm.
o 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.
Vision and Quality Inspection Systems
· Pre-Welding Alignment:
o High-resolution CCD cameras ensure ±0.02 mm positioning accuracy.
· Post-Weld Inspection:
o Surface continuity and defect detection via AI-based algorithms.
· Adhesive Application Check:
o Vision-guided inspection with adjustable thresholds.
· Data Logging:
o Process results saved to a central server in CSV format.
Control and Interface
· Control System: Centralized PLC with distributed modular controllers for each station.
· HMI:
o 15-inch touchscreen with multilingual support.
o Real-time process monitoring and troubleshooting.
· IoT Connectivity:
o Remote diagnostics and software updates via Ethernet or cloud.
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.
Electrical Specifications
· Power Supply: AC 380V ± 10%, 50/60 Hz, 3-phase.
· Maximum Power Consumption: 50 kW.
· Control Voltage: 24V DC for auxiliary systems.
Cooling System
· Type: Water cooling system for laser and electronic components.
· Cooling Capacity: 20 kW.
· Flow Rate: 10–20 L/min.
Environmental Requirements
· Operating Environment:
o Temperature: 15–30°C.
o Humidity: ≤60% RH (non-condensing).
· Noise Level: ≤70 dB during operation.
· Installation Space: Minimum clearance of 1,500 mm around the line.
Maintenance and Warranty
· Maintenance Schedule:
o Weekly: Inspect lenses, alignment systems, and sensors.
o Monthly: Calibrate laser systems and check adhesive applicators.
o Quarterly: Full diagnostics of mechanical and electrical systems.
· Warranty Period:
o Standard: 12 months.
