Intelligent upgrade of lithium battery winding machine: a comprehensive solution from efficiency improvement to yield control

Intelligent upgrade of lithium battery winding machine: a comprehensive solution from efficiency improvement to yield control
The intelligent upgrade of lithium battery winding machines is achieving a synergistic breakthrough in efficiency and yield through multidimensional technological innovation. The following is the core path of a comprehensive solution:

1、 Efficiency improvement: high-speed collaboration and flexible production

High precision motion control

Adopting EtherCAT bus technology to achieve millisecond level synchronous control of the needle and pole feeding mechanism, the winding line speed is increased to over 20mmin, and the correction accuracy reaches ± 0.02mm.
The dynamic tension closed-loop system combined with the floating roller buffer mechanism allows the diaphragm tension to fluctuate by ± 1 °, avoiding material tensile deformation or fracture.

Flexible changeover and modular design

The quick change fixture and adaptive programming system compress the product changeover time from 2 hours to 15 minutes, supporting mixed production of multiple battery models.
The dual station needle structure, combined with an automatic coil changing system, achieves continuous production and increases the overall equipment efficiency (OEE) by 25%.
2、 Yield control: closed-loop quality control throughout the entire process

AI vision real-time quality inspection

Industrial cameras and deep learning models are used for online detection of polarizer alignment and weld defects (with an accuracy of 5 μ m), resulting in a near zero missed detection rate and an improved yield rate of 99.8%.
Diaphragm defect detection sensor (response time 30ms) eliminates the risk of misdelivery of single and double pole plates.

Intelligent optimization of process parameters

Vlink IoT platform collects over 200 parameters in milliseconds, including winding speed, temperature, and polarizer length, and dynamically optimizes process formulas by correlating historical yield data.
The digital twin model rehearses the winding process, avoiding risks such as insufficient pole wrapping and inner ring breakage in advance, and shortening the trial production cycle by 40%.

Dynamic compensation technology

Constructing a roll diameter variation model based on Archimedes' spiral law, adjusting the motor speed in real-time to maintain a constant wire speed for winding, and solving the GAP problem of square battery cells.
🌐  3、 System architecture upgrade: Cloud edge collaboration and intelligent operation and maintenance
Global data connectivity
The industrial gateway is directly connected to the PLC, synchronizing equipment status and process data to the MESERP system, eliminating information silos.
Predictive maintenance system
Analyzing data on motor vibration, temperature drift, etc., the accuracy of fault warning is 90%, and unplanned shutdowns are reduced by 30%.
Closed loop operation and maintenance knowledge base
Solution for sedimentation faults in the automated production order system (dispatch acceptance review), with a 50% increase in maintenance response speed.
🔮  4、 Future Trends
Process integration: Laser die-cutting and winding machines are gradually becoming popular, reducing damage during the transportation of polarizer.
Green Manufacturing: The energy consumption monitoring platform optimizes peak and valley electricity scheduling, reducing single machine electricity consumption by 15%.

The essence of intelligent upgrading is "data-driven technology": capturing micro changes in the physical world through high-precision sensing (such as ± 0.1N tension fluctuations), and then converting them into executable optimization instructions through algorithms, ultimately achieving the ultimate goal of "zero defect" winding.