How can sensors solve the pain points in lithium battery production, such as abnormal material feeding, uneven coating thickness, and unqualified pole height?

Lithium battery manufacturing features complex processes, high technical barriers and stringent quality standards. Improper process control will directly impair the performance and quality of finished batteries.

Battery manufacturers have set higher requirements for production equipment in terms of precision, efficiency, intelligent maintenance and fault diagnosis capabilities.

Promoting intelligent upgrading to boost production efficiency and product quality has become an imperative task for lithium battery enterprises.

As the core sensing component and the source of data collection, sensors are widely applied throughout the automated production of lithium batteries.

This article gives a detailed analysis of sensor application solutions for key working stations in automated battery manufacturing.

Cell Blanking Detection

Application Scenario

At the cell blanking station, it is required to detect whether materials are properly fed to the designated position. Inaccurate cell feeding will cause idle running or material jamming in subsequent processes, disrupting the tact time of the entire production line.

Solution

Adopt Heyi FM-E23 Series Fiber Optic Sensor + FN-T001(R) Fiber Optic Head

Comprehensive circuit protection with reverse polarity protection and over current protection

Excellent working stability

High precision with regional detection capability

Fast response speed up to 50μm

Single & Double Sheet Detection of Pole Sheets for Stacking Machine

Application Scenario

In the stacking process, it is necessary to identify single and overlapping pole sheets. If two pole sheets enter the stacking station simultaneously, it will lead to the risk of internal short circuit of the battery, which is a critical quality defect.

Solution

Adopt Heyi UDC Series Ultrasonic Sensor for Single & Double Sheet Detection

Built-in temperature compensation, free from ambient temperature impact

Ultrasonic system for reliable detection of missing sheet, single sheet, double sheets and overlapping sheets

Applicable to single/double sheet detection of various materials

Self-learning function via multi-function input; parameters can be remotely set through cables

Completely unaffected by dust, dirt and fog

Strong anti-interference performance against electromagnetic and radio frequency interference
 

Lithium Battery Electrode Coating Thickness Detection

Application Scenario

Battery electrodes are mainly made of copper foil and aluminum foil. Coating is applied on the electrode surface to improve current conduction efficiency between two poles. Full inspection of pole sheet thickness is essential to ensure accurate and uniform coating thickness.

Solution

Adopt Heyi LC-S Series CMOS Laser Displacement Sensor

Non-contact detection

Optional short, medium and long detection distances

Compact structure, tiny light spot and high precision

Multiple output modes: single switch output, dual switch & analog output, RS485 communication output

Rich built-in functions and detection modes to adapt to diverse application scenarios

Pole Height Detection of Lithium Battery Modules

Application Scenario

After the assembly of lithium battery modules, pole height inspection is required to ensure product qualification.

Solution

Adopt Heyi HK-S Series High-precision Digital Contact Displacement Sensor

Micron-level repeat accuracy

High-precision grating measuring principle

Multi-digit digital display for measured values

Resolution up to 0.1μm

Detection accuracy up to 1μm with no cumulative error

Optional RS485 / RS232 communication output

Support operation with matched amplifier or standalone use of detection head

Equipment & Personal Safety Protection

Application Scenario

When personnel approach hazardous areas, the sensor outputs signals to cut off power of operating equipment such as manipulators and cutting machines, so as to avoid safety accidents.

Solution

Adopt Heyi GM-L Series General-purpose Safety Light Curtain

Complete self-check function and high resolution

Resist electromagnetic, laser and ambient light interference

Optional multi-channel and multi-signal output

Optical synchronization and line synchronization available for the full series

Optional S-type external controller for multi-scenario protection

Shockproof, waterproof and dustproof performance

LED indicator for working status and fault alarm

Barcode Identification & Reading

Application Scenario

At the casing station of prismatic lithium batteries in the middle production process, bare cells are loaded into the shell, and the cell cover is pre-welded with the shell mouth. QR codes on the battery cover need to be identified before casing operation.

Solution

Adopt Heyi SV Series AI Vision Sensor

Auto focus and brightness correction

High-speed detection capability

Megapixel resolution, supporting long-distance and wide-field detection

Integrated multiple detection functions:

Color recognition, contour comparison, area measurement, brightness identification, position correction, width & diameter detection, edge presence detection, pitch measurement, character recognition, barcode recognition, etc.

The rapid capacity expansion of power batteries in China has raised extremely high standards for the automation level of production equipment.

Integrating sensing technology with lithium battery manufacturing technology,Heyi Sensor is committed to providing comprehensive sensor solutions for the lithium battery industry. We help realize higher efficiency and intelligence in lithium battery production, and drive the development of the new energy lithium battery industry.