44 Space and energy savings are the main efficiency drivers associated with this process. It simplifies the coating by positioning the coater and dryer on one level, reducing the required ceiling height by about 5 m and improving access, he explains. Drying both sides of the electrode at once also saves energy. French calendaring specialist Ingecal, part of Dürr group since 2023, uses ‘dynamic gap control’ for closed-loop handling of coating thickness, based on accurate measurement. This enhances energy density and performance. Turning to winding and stacking machinery for cylindrical and prismatic/ pouch cells, respectively, progress is also being directed towards greater speed and precision. Beckhoff’s cylindrical cell windingcontrol systems are based on a central, PC-based automation platform that controls vision systems, motion tasks and communications to inputs and outputs (I/Os) with a high level of synchronicity, which enables high-volume output and great accuracy, the company explains. Efficiency and quality The way data is handled has a big impact on quality, says Beckhoff’s Rottkord: “The fact that process data, parameter sets and recipe data, besides diagnostics and measurement, can all be handled on the same control unit make the systems more seamless, reliable and scalable. Potential problems are detected immediately and can be reacted to right away.” Virtualisation technologies such as system twin are intended to improve efficiency, throughput and quality by enabling battery manufacturers to benchmark the performance and troubleshoot automated production systems before their lines are built, says ATS Industrial Automation’s Echter. “By identifying and mitigating risks before physical build, battery companies can develop more cost-efficient processes that have a higher throughput,” Echter says. “What’s more, they can test and optimise these processes as often as needed within the simulated environment. They don’t need expensive physical parts or prototypes for testing.” System-twin technology can be used to mitigate the risks inherent in designing, testing and commissioning a battery line, and also cut costs and lead times. “Both system twinning and digital twinning of individual machines can enable error handling and the offline programming of robotics, programmable logic controllers (PLCs) and third-party equipment to debug and troubleshoot errors early on in the design process. What’s more, system twinning can also run in parallel with live production lines, making it possible to test, validate and apply continuous improvements without machine downtime,” says Echter. Improvements in throughput, efficiency and quality can also be achieved through the continuous mixing of active electrode compounds, says Coperion’s Bernert. When combined with high-accuracy feeders, twin-screw extruders offer good process stability, precision and reliability. Further benefits include a reduction in the space and number of people required, compared with batch-mixing processes, as well as less downtime and lower costs. Generating a specific torque of 18 Nm per cm3 of mixture volume, the company’s ZSK Mc18 twin-screw extruder offers highly dispersive mixing and high throughput. Subsequent distributive mixing ensures the high level of homogeneity required in electrode compounds, he says. “The process Insight | Battery production technology July/August 2024 | E-Mobility Engineering Air flotation drying is an attractive option for electrodes as it eliminates potentially damaging physical contact with coating during drying (Image courtesy of Dürr Systems) There is commonality in robotics and automation in the manufacturing of batteries and fuel cells to improve efficiency, and reduce damage risk (Image courtesy of ATS Industrial Automation)
RkJQdWJsaXNoZXIy MjI2Mzk4