Lithium batteries are a commonly used type of battery, with advantages such as high energy density, long lifespan, and lightweight, and are therefore widely used in various fields.
The lithium battery coating process refers to the process of coating lithium batteries. It can not only protect the internal structure of the battery, but also improve the safety and lifespan of the battery.
The Decowell RB series card-type I/O modules have been successfully applied in the lithium battery coating process due to their high stability and high precision.
1. Industry Analysis
The outer film of a lithium battery is a special plastic film whose main function is to protect the lithium battery from the influence of the external environment and prevent battery performance degradation or safety accidents caused by physical impact, temperature changes, humidity changes, etc.
The outer coating can maintain the integrity of the electrolyte and electrodes inside the battery, preventing the intrusion of moisture, oxygen and other harmful substances, thereby extending the battery's lifespan and ensuring its safety performance.
Lithium battery coating involves the packaging and testing of the battery. By dividing the outer surface of the battery into regions for coating, pressure is applied to the insulating film of the overlapping part in the first coating region of the battery to reduce the height difference of the overlapping part of the insulating film, and then the insulating film of the first coating region is subjected to surface activation treatment.
Applying adhesive to the insulating film in the first encapsulation area and then curing the adhesive can provide some protection for the outer surface of the battery, further improve the battery's insulation performance, meet the battery's insulation performance requirements, and enhance the battery's safety in use.
2. Pain points on site
The core challenges in lithium battery coating processes are issues related to process control and equipment precision, which directly affect battery performance and safety. Therefore, strict requirements are placed on the electrical control system during production.
1. Adaptable to complex processes
The lithium battery packaging and testing process includes multiple stages such as cell manufacturing, grading, assembly, testing, packaging, and quality inspection. Among them, the lithium battery packaging coating process is a mirror production process with a large number of digital signal points, approximately 2,000 points per line.
The Dekwell RB series I/O modules are highly expandable and compatible, and can be flexibly adapted to lithium battery coating processes.
2. Improve equipment accuracy
Precise coating processes are crucial for the performance and safety of lithium batteries. During the coating process, precise control of the work station and temperature is required, which places demands on the real-time performance of the I/O modules.
The signal response cycle of the Dekwell RB series card modules is within 4ms, which provides high real-time performance and ensures the accuracy of each step in the coating process.
3. Ensure communication stability
The intermediate process in lithium battery coating includes insulation withstand voltage testing, which requires high EMC protection performance. Simultaneously, the communication topology of the electrical control system for this process involves numerous servo electrical components; if any station malfunctions, the entire production line will be affected, thus requiring high stability.
The Dekwell RB series I/O modules currently achieve an EMC protection level of A and have passed the ETG Association's conformance certification, ensuring stable operation and reducing interference.
3. The Deckerwell Plan
The coating machine's production process consists of several parts, including material handling, film application, short-circuit detection, and unloading. This equipment is mainly used in the coating process of lithium batteries, which also includes testing processes such as lithium battery insulation detection and leakage current detection.
The system is equipped with Dekewell RB card-type I/O modules to expand the number of input and output points. The input signals include: start, stop, emergency stop, battery cell motor front limit, battery cell motor origin, battery cell motor rear limit, battery cell motor alarm, film application quality detection, short circuit detection, photoelectric switch detection of cylinder positioning, and sensor detection of whether the tape is applied to the battery cell each time.
Outputs include: forward and reverse rotation of the battery cell motor, forward and reverse rotation of the feeding motor, vacuum solenoid valve for applying adhesive tape, and short-circuit detection cylinder solenoid valve, etc.
The cabinet houses remote I/O and servo controllers in a distributed configuration for easy maintenance. It is also equipped with a Manufacturing Execution System (MES) to monitor total production volume and output allocation within the factory.
Using a Siemens PLC controller master station, paired with a Decowell RB-1110 card-type remote I/O, the system controls the allocation of production tasks within the factory. Employing dual-line mirror production, the system significantly improves product output efficiency, offering a clear cost-performance advantage and excellent anti-interference performance.
Main station: Siemens PLC
Applicable process segment: Lithium battery coating process segment
Project I/O configuration: 3*RB-1110 + 12*16DI + 9*16DO
4. Product Introduction
RB series ultra-thin card-type I/O
The new generation of three-section card-type modules is as thin as 12mm per module. The three-section design supports hot-swapping, making it convenient for on-site maintenance and replacement.
Features:
1. Supports large-diameter terminals, eliminating the need for tool-based wiring;
2. The communication interface is designed at a 45-degree angle to reduce stress;
3. Multiple protections including overcurrent and reverse connection protection;
4. Hot-swappable function, online maintenance without system shutdown;
5. Powerful diagnostic capabilities, supporting module-level and channel-level diagnostics;
6. DIN35 rail-mounted spring-loaded knob, one-step installation;
