Leveraging New Technology for Advancements in Battery Electrode Manufacturing

Machine designers and process engineers in the battery industry are witnessing a pivotal shift towards more space-efficient, precise, and adaptable manufacturing processes. To this end, the industry is increasingly focused on achieving more electrode lanes per machine, while integrating advanced sensor technologies to meet the growing demand for high-quality batteries used in EVs and grid storage applications.

A cantilevered, Segmented Tension Roll® measuring multiple electrode lanes

SPACE OPTIMIZATION IN MULTI-LANE SETUPS
The challenge of managing multiple lanes within the limited space of manufacturing lines is being addressed through innovative solutions like DFE’s Segmented Tension Roll® Transducer. This device allows for the measurement and control of tension across multiple web strands (or lanes) with a single, compact unit. By eliminating the need to deploy a large array of individual tension sensors, it significantly minimizes the machinery footprint, enabling battery manufacturers to increase production capacity and enhance operational efficiency without expanding physical space.

PRECISION AND FLEXIBILITY WITH SEMICONDUCTOR STRAIN GAUGE TECHNOLOGY
Precision in tension control is crucial for producing electrodes with consistent thickness and quality. The integration of semiconductor strain gauge technology within tools like the Segmented Tension Roll® provides engineers with a load cell system that delivers up to 50 times more sensitivity than foil gauge sensors, able to detect and adjust to the slightest shifts in tension – even in the presence of high EMI. This technology not only ensures optimum coating, calendaring or slitting across all lanes, but also the flexibility to adapt to different chemistries, substrates or process conditions as manufacturing needs evolve over time.

ENHANCED CONTROL SYSTEMS FOR PROGRAMMABLE LOGIC CONTROLLERS
Some low-cost, commodity load cell amplifiers use inexpensive ADCs that rely on gain blocks to boost signal performance. The high gain signal is then conditioned using a variety of filtration techniques. Typically, this averaging approach results in increased signal latency while also delivering “choppy” output, resulting in sluggish, interpolated data streams.

In contrast, DFE’s synergy between the Segmented Tension Roll® and TA500 amplifier has transformed what’s possible for tension measurement. TA500 amplifiers with high-quality 24-bit ADCs downconvert signals to 16-bit in real-time, sending noise-free raw data from each Tension Roll® segment directly to the ethernet bus. This allows for incredibly precise and responsive torque and speed adjustments in any control zone. This pairing is crucial for closed-loop systems where immediate feedback and control is necessary to maintain the integrity of delicate electrode coatings and substrates, particularly at high processing speeds.

PRACTICAL BENEFITS FOR BATTERY MANUFACTURING

• Consistent Quality: By ensuring uniform tension across multiple lanes, the risk of defects like uneven coating or material stretching is minimized, leading to higher quality electrodes and increased yields.
• Operational Efficiency: The ability to quickly recalibrate or adjust tension for different materials or process requirements enhances the line’s adaptability to production changes, reducing downtime and increasing throughput.
• Space and Cost Savings: The compact nature of solutions like the Segmented Tension Roll® combined with the resolution and precision of TA500 amplifiers means less space is required for tension management, lowering both initial investment and ongoing operational costs.

INTEGRATION AND IMPLEMENTATION
For engineers and machine-builders, integrating these technologies into existing setups has become easier than ever. The Segmented Tension Roll® is designed for easy retrofit or inclusion in new machinery, with each segment capable of independent calibration to meet specific production needs. Meanwhile, the TA500 amplifiers serve as the backbone for processing sensor data, ensuring that control systems can react with the necessary speed and precision to achieve production goals.

FUTURE DIRECTIONS
The adoption of these technologies signals a broader industry trend towards smarter, more integrated manufacturing solutions. As battery demand continues to grow, especially with the rise of electric vehicles and renewable energy storage, the focus on space efficiency, precision, and process adaptability will only intensify. For engineers in this field, the Segmented Tension Roll® and TA500 amplifiers are not just tools but enablers of this future, providing the means to achieve higher production standards with fewer resources.

In conclusion, the battery electrode manufacturing sector is clearly moving towards leveraging advanced tension control systems like those offered by DFE, setting a new standard for what’s possible in terms of efficiency, quality, and adaptability in manufacturing.

Typical multi-lane tension control solutions incorporate:

• Load cell signal amplifiers such as the TA500-ECAT, TA500-EIP or TA1

• Segmented Tension Roll® Transducers