Lithium-ion battery production is a technical challenge that is dependent on many processes working just right to ensure quality and consistency. Any flaws can severely impact plant availability and manufacturing throughput. This is because defects during manufacturing can not only shut down production lines when they are needed most, but can also potentially lead to safety issues for end-users and increase the risk of expensive product recalls.
That's why the fragile metal foils that form the core of the batteries require extremely careful handing at every stage of manufacturing, from initial coating and drying to calendering, cutting splitting, and final assembly.
The slightest imperfection at any stage can cause significant performance and safety issues in a finished battery. That's why it's vital to automate quality control and most aspects of production throughout with precision robotics to ensure safety, consistency, and productivity.
Accurately measuring and monitoring the movement of very thin, fast-moving coated metal foils presents specific challenges. Precision control and consistency of flatness and tension, for example, are essential to avoid the slightest component distortion, which can negatively impact battery performance, reliability, and safety.
This can be particularly challenging in factory environments, where equipment must be able to withstand a wide range of physical forces and, often, temperature extremes. Equipment calibration in such environments is crucial because if measurements go wrong, such imperfections can halt production for hours.