Fully Automatic Lithium-Ion Battery Electrode Die Cutting Machine

1. Equipment Overview

1.1 Equipment Function Description

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

The electrode roll is loaded onto the unwinding air expansion shaft by AGV or manually. The equipment performs automatic unwinding, with the deviation correction mechanism ensuring real-time correction during unwinding. The unwinding tension is controlled via a tension control system. A secondary deviation correction (process correction) is performed before laser die cutting.

At the punching station, laser cutting forms the electrode tabs. The material is then conveyed through a traction unit, cleaned by air knife dust removal, and passed through a tension control unit and buffering module. Subsequently, metal die cutting is used for inner corner punching. The electrode is inspected by CCD for defects, conveyed to the cutting station by the pulling unit, and cut into sheets.

Finished products are transported via conveyor belts for dimensional inspection, by double-sided powder brushing detection. Non-conforming products are automatically rejected into the NG bin, while qualified products are collected in the finished product bin.

1.2 Operation Process Flow

1.3 Equipment Layout (for reference only)

Main body dimensions: approximately 7500 × 2000 × 2600 mm

1.4 Equipment Features

1. Unwinding Module: The specially designed air-expansion shaft reduces friction between the coil and shaft, saving time and effort during material changes. Automatic unwinding is driven by servo motors and controlled by programs that calculate roll diameter variations. When the material roll nears depletion, the machine issues an alarm and stops automatically.

2. Material Pulling Unit: Uses a patented servo-driven mechanism with a pulling accuracy of ±0.2 mm.

3. Buffering System: Integrated servo and module-driven buffering system in coordination with the tension control ensures continuous unwinding during die cutting and improves production efficiency and feeding accuracy.

4. Electrode Cutting Mechanism: Patented cutting system with minimal burrs and dust. Cutting width can be adjusted via servo control according to electrode sheet size, improving sheet width precision.

5. Integrated Functions: Supports CCD inspection and powder brushing, increasing overall equipment utilization.

6. Dust Removal: Patented dust-removal structure reduces secondary contamination and protects electrode surfaces during brushing.

7. Laser Tab Cutting: Significantly reduces the forming cost of electrode sheets.

8. Tape Handling: Automatic avoidance of cutting blades during tape die cutting prevents damage to molds and cutters.

9. Sheet Collection Accuracy: Servo punching mode with sheet collection precision of ±1 mm.

10. Dust Control Zones: Partitioned dust control areas equipped with internal FFU filtration systems to achieve ISO Class 100,000 cleanliness inside the equipment.

11. MES Communication: Reserved dual network ports for MES connectivity.

2. Equipment-Compatible Raw Material and Product Specifications

2.1 Compatible Raw Material Specifications

2.2 Electrode Sheet Die Cutting Method

2.3 Customer Product Size Confirmation Table

2.4 Electrode Sheet Burrs

l Flat burr (Vk, metallic burr): ≤ 10 µm

l Vertical burr (Vh, metallic burr): ≤ 18 µm

3. Technical Parameters of Equipment

4. Main Components and Functions

4.2.1 Unwinding Module

l Unwinding direction can be clockwise or counterclockwise.

l Fiber optic pen assists in positioning the electrode roll during loading.

l Unwinding module includes automatic web guiding with ±0.2 mm accuracy and ±50 mm correction range.

4.2.2 Splicing Module

l Equipped with a roll splicing platform, with alignment lines to assist manual splicing.

l Dust collection box installed at cutting area; dust is extracted via negative pressure for cleanliness.

4.2.3 Tension Control Module

l Dancer roller type synchronous speed control; potentiometer feedback to PLC, which controls servo motor speed.

l Tension controlled via PLC + low-friction cylinders + electronic proportional valve.

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

4.2.4 Intermediate Web Guiding (Process Correction)

l Equipped with a high-precision guiding module; user-friendly operation with manual fine-tuning.

l Correction accuracy: ≤±0.1 mm; correction range: ±20 mm.

4.2.5 Laser Cutting Module

l 250 W fiber laser with adjustable pulse width; power stability <5%.

l Laser lifespan >50,000 hours.

l Single-station laser cutting system with precise dimensions and clean separation.

l Detection of cut/non-cut tabs on both tab and non-tab sides.

l Tape jump cutting supported (skip cutting after detection of tape); spacing between tab and joint adjustable for material utilization.

l Cutting area enclosed with a semi-sealed dust cover; particles removed by air knives and vacuum suction, airflow ≥15 m/s.

l Air knife distance and angle adjustable; digital pressure gauges for positive/negative pressure pipes.

l Equipped with safety door interlocks, light curtains, and dual-button jog mode.

l Laser protective window made of laser shielding glass.

l Laser cutting waste collected by vacuum system and centralized pipeline.

l Metal piping used within 1 meter of laser head; flame-retardant material for others.

l Cutting system supports both equal-interval and non-equal-interval modes.

4.2.6 Buffering Unit

l Servo + precision screw drive buffer unit works in conjunction with tension system.

l Lightweight rollers minimize inertia and enhance stability.

l Carbon fiber guide rollers; electronic cam control used.

4.2.7 V-Notch Punching Unit

l Two V-notch dies form tab shapes.

l Includes auto web-guiding system via sensors for accurate punch alignment.

l 2-color mark sensors detect tape for skip punching.

l Equipped with safety light curtain for human-machine safety.

l Die base made of granite for high flatness (≤0.01 mm).

l Quick die mounting system enables changeover <0.5 hr.

4.2.8 Feeding Mechanism

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

l EPDM rubber rollers ensure flat surface and no particle buildup.

l Upper roller rubber-coated (90 Shore hardness), maintains tight contact with lower roller.

l Lower roller is chrome-plated HV750 steel, Ra ≤0.2.

l Upper roller is air-cylinder-pressurized for accuracy.

l Cutter driven by servo motor + cam system.

l Blade made of imported G5 tungsten steel.

l Blade replacement time ≤0.5 hr.

4.2.9 Belt Conveyor System

A. Upper Conveyor:

l Driven by servo motor; electronic cam curve ensures smooth motion.

l 3 mm holes in belt for vacuum suction.

l Automatic brush cleaning; belt made of 1.5 mm thick PU top + PVC bottom material.

l Integrated with dimension CCD and surface dust removal.

B. Lower Conveyor:

l Driven by servo motor; same electronic cam mechanism.

l 3 mm holes for vacuum suction; belt split into multiple tracks.

l Automatic brush cleaning; same PU+PVC belt material.

l Includes electrode drop-off and bottom-side dust removal.

4.2.10 Powder Brushing Unit

l Cleans electrode surfaces and removes cutting dust.

l Centralized dust filtration system prevents spread of powder.

l Combines ionized air blowing and suction for powerful cleaning.

l Equipped with 10,000 Gs magnets to remove ferromagnetic particles.

l Dust extraction at unwinding, die-cutting, and trimming areas.

l Stubborn powder brushed off with mechanical brushes.

l Dust removal noise ≤75 dB.

4.2.11 Electrode Sheet Collection System

l Electrodes conveyed to collection box, which has auto-lifting and full-material alarm functions.

l Includes buffering mechanism and separate NG/OK boxes.

l Stacking without edge collisions, neatness ≤±1 mm.

l Collected via suction conveyor; stacking controlled by stepper motor.

l Emergency stop button placed in discharge area.

l NG sheet logic: 3 consecutive bad → alarm; 5 consecutive bad → machine stops.

4.2.12 Defect Detection

l Uses linear scan cameras to scan and stitch full images of electrode surfaces.

l Custom image analysis algorithms identify defects; NG sheets auto-rejected.

l Two 4K line-scan monochrome industrial cameras + 400 mm light source.

l Front/back surface data exported as CSV.

l AI-based defect classification supported.

Defect Types and Thresholds: 

4.2.13 CCD Dimension Detection

l Captures tab height and foil exposure using area-scan industrial cameras.

l Measures length, edge distance, tab width, and angle.

l Accuracy: ±0.1 mm, Miss Rate = 0, False Positive Rate ≤ 0.3%.

l Uses backlight for higher precision; flattening roller improves image quality.

l Dimension parameters include: sheet width, height, angle, tab shoulder width, and tab carry-over length.

4.2.14 Control System

l Includes 1 PLC + 15" touchscreen and other electrical components.

l Bus-type wiring for cleaner, simplified connections.

 

4.2.15 Machine Frame & Enclosure

l Welded square tube steel frame, surface spray-coated.

l Enclosure made of aluminum or sheet metal + acrylic.

l FFU filter units installed on top to supply clean air.

l Internal cleanliness ≥ Class 100,000.

5. Main Components List

5.1 Main Configuration List

No.	Main Component	Brand	Origin
1	PLC Control System	Trio	United Kingdom
2	Web Guiding System	Puliyuan / Bat	China
3	Touchscreen	Weintek	China
4	Servo Motor	Estun	China
5	Tension Controller	Fujikura	Japan
6	Pneumatic Components	SMC / Airtac	Japan / Taiwan
7	Ball Screw and Guide Rail	Hiwin	Taiwan
8	Bearings	NSK	Japan
9	Electrical Switch Components	Schneider / Panasonic	Germany / Japan
10	Photoelectric Sensors	Omron / Panasonic / Baumer / Julong	Japan / China
11	CCD Camera	Hikvision	China
12	Laser Control System	Self-developed by Yixinfeng	China

5.2 List of Consumable Parts

No.	Name	Specification	Remarks
1	Photoelectric Switch	EE-SX671A	Omron
2	Intermediate Relay	MY2J-12VDC	Schneider
3	Push Button Switch	φ22	Schneider