1 Introduction
The manufacturing process of lithium batteries is relatively complex, mainly encompassing three stages: pre-production, mid-production, and post-production. The pre-production stage involves processing raw materials into electrode sheets through processes such as coating, rolling, slitting, sheet forming, and die-cutting, with coating being the core process. The mid-production stage involves processing the electrode sheets into unactivated cells, requiring processes such as winding or stacking, casing welding, electrolyte injection, and sealing, with winding and stacking being the core processes. The post-production stage involves activating the cells to create finished battery packs, which are then integrated into the battery factory via a PACK system. This includes processes such as cleaning, drying, storage, testing, coding, and capacity testing, ultimately entering downstream production lines via an automated intelligent logistics system. The fully automated polymer lithium battery packaging machine introduced here is located in the mid-production stage of lithium battery manufacturing, encompassing processes such as casing welding, electrolyte injection, and sealing. This fully automated polymer lithium battery packaging machine is specifically designed for the online production of micro-sized polymer cells, primarily used for the packaging and molding of polymer soft-pack cells. The design facilitates connection with front (winding machine) and back (baking oven) process equipment or allows it to function as a standalone device. It uses a servo motor to enable one-touch model changeover.
This equipment is equipped with functions including aluminum-plastic film forming, core pressing and shaping, CCD detection of core tab spacing, robot feeding of cores into the forming film, top sealing of cells, side and corner sealing of cells, internal resistance testing, cell pre-cutting, CCD detection of adhesive height on sealed core tabs, cell coding, cell barcode scanning, application of protective film to cells, and robotic loading of good cells into the cell material tray. Furthermore, the equipment requires manual feeding of aluminum film rolls, feeding of incoming cores into the equipment via blister packs, manual feeding of empty cell material trays into the equipment, and automatic loading of cells (finished cells).
2. Use of products
Products used include: Jelly Roll cores, Polymer batteries, molded films (50-100mm wide), and battery cells.
3. Equipment layout diagram (see Figure 1)
Figure 1. Layout diagram of lithium battery packaging equipment
4. Production process flow of the integrated automatic packaging machine for polymer lithium batteries (see Figure 2)
Figure 2. Flowchart of the production process of the lithium battery automated packaging machine
5. Field Network Solutions
Today's production environments demand higher productivity and product quality, requiring networks that can ensure real-time performance while connecting various devices. These networks must enable high-speed, stable control, support large-volume data transmission to IT systems, and be applicable to AI and predictive maintenance. CC-Link IE TSN, by redefining communication methods and significantly improving performance, allows for the coexistence of general Ethernet and control communication, connecting to various general Ethernet devices without affecting control communication. Furthermore, its support for diverse network topologies facilitates the easy construction of flexible IIoT systems.
Based on equipment requirements, we recommend that customers adopt an eF@actory system comprised of an MES network, a CC-Link IE TSN network, and a CC-Link network. The MES network serves as the information layer network for database communication between the field and the upper control unit. The CC-Link IE TSN network is used for servo control communication and remote I/O communication, while the CC-Link network is used for communication between robots, electric cylinders, etc.
6 System Configuration and Network Architecture
6.1 System Configuration (see Table 1)
Table 1 System Configuration Table
6.2 Overall Network Architecture (see Figure 3)
Figure 3 System Network Architecture Diagram
7 CC-Link IE TSN Network Advantages
TSN is a supplement to the IEEE-defined standards related to Ethernet, enabling accurate information transmission over standard Ethernet. By utilizing time synchronization (IEEE 802.1AS) and time division (IEEE 802.1Qbv) methods, combined with Ethernet technology, it is possible to achieve the coexistence of control communication (ensuring real-time performance) and information communication (non-real-time communication) in the same network, which was previously impossible with Ethernet.
7.1 Integrating protocols and TSN technology that support high-speed and high-capacity communication
CC-Link IE TSN is a network composed of a high-speed cyclic communication protocol and TSN technology. In today's production environments, high-capacity data transmission is required alongside high-speed and stable control communication. By employing TSN technology, the control communication needed for equipment operation is not affected, and it can be used simultaneously with TCP/IP communication. Furthermore, by implementing a high-speed, high-capacity communication protocol, cycle time can be reduced, and productivity can be improved.
7.2 Optimize the communication cycle of a system with devices of different communication performance.
High-speed communication devices (for high-speed, high-precision control) and low-speed communication devices (for status monitoring) can be used in combination. The communication cycle of each device can be adjusted as needed to set the most suitable communication cycle for the device's function. For example, for slave devices requiring high-speed, high-precision control, a high-speed cycle can be used for communication; for slave devices requiring status monitoring, where low-speed communication can meet the needs, a low-speed cycle can be used.
7.3 Utilize rich features to build a convenient communication network
The CC-Link IE TSN supports GXWorks 3 and SNMP-based third-party monitoring and diagnostic tools, making it a network capable of utilizing a variety of diagnostic functions. Furthermore, it can automatically send parameters from the master module, simplifying the setup of slave devices and significantly reducing manpower.
7.4 TSN Technology and Communication Protocol Layer
CC-Link IE TSN optimizes communication frames through time synchronization and time division technologies, enabling high-performance, high-function control communication while also allowing coexistence with other Ethernet communications. Furthermore, its diagnostic functions utilize the Ethernet standard protocol SNMP, making it easier to effectively utilize common Ethernet devices and diagnostic tools.
7.5 Seamless communication across the entire network
By integrating IT data using TCP/IP communication and control data using CC-Link IE TSN, seamless communication is achieved across the entire network. The transmission of large volumes of IT data, such as image data from vision sensors, does not affect the transmission of control data. Simultaneously, applications such as transmitting continuous data from multiple devices, using artificial intelligence (AI), and advanced predictive maintenance utilizing edge computing can coexist.
7.6 Integrate communication between OPC UA and IT systems, as well as communication with devices supporting multiple protocols, to achieve factory intelligence.
Seamless network communication is achieved, from upper-level IT systems down to lower-level sensors, regardless of network layer differences. Since various system architectures can be built using only a single network, equipment and software costs can be significantly reduced.
The features of the CC-Link IE TSN network described above are used to meet customer technical requirements.
8. Network Structure of Control System
8.1 Ethernet Network
The Ethernet network is an MES network composed of Mitsubishi Electric RD81 MES96 modules, connected to the server. Information such as production status, alarm information, and product barcode information is automatically uploaded to the server, allowing company managers to monitor production status in real time. In addition, information on related products being manufactured can be downloaded from the server and compared with the status of products currently in production to prevent defective products and improve production efficiency.
8.2 CC-Link IE TSN Network (see Figure 4)
The CC-Link IE TSN network is mainly used for servo control communication and remote I/O communication.
Figure 4 CC-Link IE TSN Network
①TSN network
• It enables the coexistence of control communication (ensuring real-time performance) and information communication (non-real-time communication) within the same network, requiring only one network for the entire system, significantly reducing the workload and complexity of network configuration, network connections, and procurement;
• Uses 5e Ethernet cables for connection, reducing costs and improving ease of connection;
• Network construction can be easily achieved through automatic detection of network configuration devices and sending parameters to connected stations;
• Supports multiple topologies, including linear and star topologies.
②Servo system
• The use of battery-free absolute position encoders greatly reduces the maintenance workload of battery replacement and also reduces equipment failures caused by battery failure;
• The motor power cable, encoder cable, and electromagnetic brake cable are integrated into one unit, reducing the number of cables and lowering the probability of failure;
• Predictive maintenance can detect equipment vibration and friction in advance, prompting maintenance actions such as replacing parts before equipment failure, thereby avoiding downtime and reducing maintenance time.
9. User Experience
The CC-Link IE TSN network can realize both control communication and information communication. It adopts a time-division multiplexing method, which makes the communication between the master station and the servo faster and facilitates high-precision synchronous control. It can also be built on the same network as remote I/O and frequency converters, saving customers costs and simplifying system complexity.
