Fully Automatic Electrode Die Cutting Machine for Lithium-Ion Battery

1. Equipment Overview

1.1 Equipment Function Overview

This equipment is primarily used for cutting cathode and anode sheets (continuous coating process) in the stacking process of power lithium-ion batteries.

The electrode roll is mounted on the unwinding air shaft of the machine by AGV or manually. The equipment performs automatic unwinding, with an automatic edge alignment system correcting the material during unwinding. Tension is controlled by the tension control system. Before die cutting, a secondary alignment (full web correction) is performed.

After unwinding and buffering, the tab forming station uses a hardware die to punch and form the tabs. A CCD system detects defects on both front and back sides. Then, the material is pulled to the cutting position by the feeding mechanism. After cutting, the sheets are collected in the finished product tray via a conveyor belt. Defective products are automatically rejected into the NG collection box.

1.2 Action Flow

1.3 Equipment Schematic

1.3.1 Equipment Layout Diagram

1.4 Equipment Highlights

l Unwinding Module: Specially designed air shaft to reduce friction with the roll, enabling quick and easy material change. Automatic unwinding driven by servo motor, using roll diameter algorithm to determine roll usage. When the material is nearly exhausted, the system alarms and stops automatically.

l Feeding Mechanism: Uses patented servo feeding system with ±0.2 mm accuracy.

l Cutting Mechanism: Uses patented non-contact cutting structure, low dust and burrs. The cutter position is adjustable via servo motor according to the sheet size to improve width accuracy.

l Integrated Functions: Optional CCD inspection can be integrated to improve equipment utilization.

l High-Speed Precision Metal Die Punching Mechanism: Servo and eccentric wheel mechanism, fast cutting speed, low noise, stable pressure. Quick die change system with forward/backward, left/right, and angle adjustment. Equipped with independent alignment.

l Tape Bypass Function: When adhesive tape is detected, the cutting knife automatically avoids it, preventing cutter and die damage.

l Die Cooling: Built-in cooling system to reduce blade temperature and prolong die life.

l Precision Granite Cutting Platform: Flatness up to 0.01 mm.

l Stacking Neatness: Servo-driven stacking mode, sheet stacking accuracy ±0.5 mm.

l MES Communication: Two network ports reserved. Hierarchical operation control for convenience.

2. Applicable Incoming Materials and Product Specifications

2.1 Specifications of Applicable Incoming Materials

2.2 Electrode Sheet Die-Cutting Method

2.3 Customer Product Dimension Confirmation Table

2.4 Electrode Sheet Burrs

l Flat burr (Vk, metal burr): ≤10 μm

l Vertical burr (Vh, metal burr): ≤15 μm

3. Technical Specifications

4. Main Components and Functions

4.1 Unwinding Module

l Unwinding direction: clockwise or counterclockwise selectable

l Fiber optic pen assists with alignment during loading

l Equipped with web guiding correction function: accuracy ≤±0.2 mm, stroke ±50 mm

4.2 Splice Table (Taping Station)

l Equipped with splicing platform and auxiliary marking lines for manual splicing

l Non-metal materials used; pressing bar driven by air cylinder with soft contact to avoid damage to electrode sheets

l Dust collection box under blade slot, connected to dust collector via suction pipe

l Embedded scale ruler on splicing platform

4.3 Tension Control Module

l Swing roller synchronization control; signal detected by potentiometer sent to PLC

l PLC + low-friction air cylinder + electric proportional valve for tension control

l Tension range: 20–100 N, fluctuation during stable operation ≤5%

4.4 Precision High-Speed Punching Module

l Electrode tab is formed via a complete precision metal die

l Automatic web guiding correction via CCD to ensure consistent punching position

l Dual color mark sensors detect front-side tape, enabling skip punching

l Safety baffle installed for operator protection

l Die base made of marble for flatness (≤0.01 mm), ensuring stability and preventing deformation

l Quick-change tooling system with alignment pins for easy replacement (<0.5 h)

l Light curtain safety protection required at die position

l Trim scrap collected centrally

l Die punch count monitoring with replacement alerts per preset threshold

4.5 Feeding Module (Material Feeding)

l Patented servo feeding system: max speed 60 m/min, accuracy ±0.2 mm

l EPDM rollers used to avoid dust/particles on surface; ensures flat, mark-free electrode sheets

l Upper rollers rubber-coated, 90° hardness, with brush cleaning

l Lower rollers: HV750 hardened chrome-plated steel, Ra≤0.2 μm

l Upper rollers pressed down by air cylinder to ensure dimensional accuracy

l Cutter drive: servo motor + cam mechanism

l Blade material: imported G5 tungsten steel

l Tool change time ≤0.5 h

4.6 Conveyor Belt System

A. Lower Conveyor Belt

l Servo-driven, with electronic cam motion profile for smooth acceleration

l Perforated belt (∅3 mm holes) uses vacuum suction to hold electrode sheets

B. Upper Conveyor Belt

l Servo-driven, electronic cam motion for smooth operation

l 1.5 mm thick perforated belt with vacuum suction, segmented into multiple lanes

l Integrated with discharge mechanism

4.7 Electrode Sheet Collection Unit

l Sheets are automatically stacked into collection box via belt

l Box equipped with auto-lift and full-load alarm

l Buffer unit installed for temporary sheet holding

l Drop stacking precision: ≤±0.5 mm

l No contact between electrode sheet and box wall during drop

l NG sheets removed automatically; with fail-safe alarms: 3 consecutive NGs → alarm; 5 → machine stop

4.8 Double-Side Defect Inspection

l Linear array cameras scan surface while sheet passes over roller, stitching into full image

l Algorithms analyze image features, output OK/NG signal

l NG rejection device removes defective sheets

l Two 4K line scan grayscale cameras + 300 mm high-brightness linear light source

l Detection width: up to 300 mm

l CCD system exports defect data as CSV file

l AI classifies defects by type

4.9 Control System

l Composed of one PLC, one 15-inch touchscreen, and other electrical components

l Bus-style wiring reduces cable volume; clean and organized panel

l Separation of high and low voltage wiring to reduce signal interference

4.10 Machine Frame & Enclosure

l Frame made of high-strength square steel tubes, surface treated by spraying

l Enclosure made of aluminum profile / sheet metal and acrylic for dust protection

5. Main Components List

5.1 Key Components

5.2 Wear Parts List