Fully Automatic Electrode Die Cutting Machine for Power Lithium-Ion Battery

1. Equipment Overview

1.1 Equipment Function Overview

This equipment is mainly applied to cutting cathode and anode sheets (for continuous coating processes) during the stacking stage of power lithium-ion batteries.

Electrode rolls are mounted on the machine's unwinding air shaft either by AGV or manually. The equipment realizes automatic unwinding, with an automatic edge alignment system rectifying the material during this process. Tension is managed by the tension control system. Prior to die cutting, a secondary alignment (full web correction) is carried out.

After unwinding and buffering, the tab forming station utilizes a hardware die to punch and shape the tabs. A CCD system inspects both front and back surfaces for defects. Subsequently, the material is drawn to the cutting position by the feeding mechanism. Once cut, the sheets are conveyed to the finished product tray via a conveyor belt. Defective items are automatically sorted into the NG collection box.

1.2 Action Flow

1.3 Equipment Schematic

1.3.1 Equipment Layout Diagram

1.4 Equipment Highlights

 - Unwinding Module: Features a specially designed air shaft that reduces friction with the roll for quick, easy material changes. Servo motor drives automatic unwinding, with a roll diameter algorithm tracking material usage. The system automatically alarms and stops when material is nearly exhausted.  

- Feeding Mechanism: Utilizes a patented servo feeding system with ±0.2 mm accuracy.  

- Cutting Mechanism: Adopts a patented non-contact cutting structure, minimizing dust and burrs. Cutter position is servo-adjustable based on sheet size to enhance width precision.  

- Integrated Functions: Optional CCD inspection can be integrated to boost equipment utilization.  

- High-Speed Precision Metal Die Punching Mechanism: Combines servo and eccentric wheel mechanisms for fast cutting, low noise, and stable pressure. Quick die change system with forward/backward, left/right, and angle adjustments, plus independent alignment.  

- Tape Bypass Function: Cutting knife automatically avoids adhesive tape when detected, preventing damage to the cutter and die.  

- Die Cooling: Built-in cooling system reduces blade temperature, extending die lifespan.  

- Precision Granite Cutting Platform: Boasts flatness up to 0.01 mm.  

- Stacking Neatness: Servo-driven stacking ensures ±0.5 mm sheet alignment accuracy.  

- MES Communication: Two reserved network ports. Hierarchical operation control for user 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