1. Introduction
Battery-manufacturing SPMs are precision automation systems used for electrode coating, cell assembly, electrolyte filling, testing, and packing. They ensure tight process tolerances, traceability, and high-speed output, all critical in battery cell and module production.
2. Key Machine Categories
| SPM Category | Key Functions |
|---|---|
| Electrode Coating | Slot-die, comma-bar slurry application with inline thickness control (±1 µm). |
| Drying & Calendering | Uniform drying ovens, calendering rollers for porosity control. |
| Slitting & Cutting | Rotary/laser slitters for electrode roll sizing and tab punching. |
| Cell Assembly | Robotic stacking, jelly-roll winding, tab insertion (prismatic/pouch/cylindrical). |
| Electrolyte Filling | Vacuum-based volumetric/gravimetric systems, inert-gas sealing. |
| Formation & Aging | Multi-channel battery cyclers, temperature chambers, charge/discharge profiling. |
| EOL Testing & Sorting | Inline voltage, impedance, leak testing, barcode & traceability logging. |
| Module & Pack Assembly | Tab welding, compression frames, tray insertion, smart-busbar assembly. |
| Packaging & Labeling | Auto-labelers, tray/case packers, vision-check barcode applicators. |
3. Applications
- Li-ion: Dry-room-integrated coaters, slitters, winders.
- Lead-Acid: Paste fillers, acid-fillers with splash guards and corrosion-resistant coatings.
- Pouch/Prismatic: High-speed vacuum sealers, leak testers, robotic tab-welders.
- Modules: Smart assembly cells for packs with thermal and structural alignment systems.
4. Benefits
- Tight Process Control: Maintains critical tolerances—e.g., calender gap, coating weight.
- Reduced Scrap: Inline defect detection prevents downstream loss.
- Higher Throughput: Line speeds of 10,000–50,000 cells/day per module.
- Improved Safety: Reduces human exposure to solvents, acids, and ESD risks.
- Full Traceability: MES integration for cell-level history tracking and compliance.
5. Design Considerations
- Material Compatibility: Acid/solvent resistance, clean-room or dry-room materials (e.g., stainless, PTFE).
- Cycle Time Alignment: Match speeds across coating, winding, filling, and testing.
- Environmental Controls: ESD zones, HEPA filtration, inert gas blanketing, VOC exhaust handling.
- Automation Interface: PLC, SCADA, MES-ready integration with HMI dashboards.
- Maintainability: Quick-change parts, remote diagnostics, modular spare parts.
6. Deployment Strategy
- Feasibility Analysis: Map baseline scrap, yield, and hourly throughput.
- Pilot Line: Coating + slitting + assembly trial with test chemistry.
- Dry-Room & FAT: Environmental validation and Factory Acceptance Test.
- Full Rollout: Phased deployment from electrode line to module assembly.
- Performance Dashboard: Live data on OEE, reject %, cycle times, and energy use.
- Continuous Improvement: Kaizen on recipe accuracy, changeover speed, and equipment uptime.