Lithium batteries are an excellent energy storage solution, boasting benefits such as high voltage, high energy density, and long lifespan. Despite their compact size they power many devices, from solar batteries and EV batteries to smartphones. They have become the mainstream energy storage method due to charging efficiency and reliability. As smart manufacturing gains momentum, the lithium battery industry actively seeks smart upgrades for its production lines.

Manufacturing lithium batteries requires attention to critical details, with the film coating process posing a particular challenge. Lithium batteries are composed of an anode, cathode, electrolyte, and diaphragm. Diaphragms are key components, acting as insulators, preventing short circuits, and enabling the exchange of ions. Manufacturing diaphragms involves laying down a film, uniformly depositing a coat mainly made of alumina onto this film, followed by drying in an oven and concluding with film winding.

In film coating, one of the most common bottlenecks is the sheer complexity of device brands and models, often compounded by a lack of uniform communication standards. Additionally, untimely tension control may lead to broken films and material waste. A further complication lies in the precise positioning of the coating head, which may have a considerable impact on coating quality and manufacturing efficiency.

Delta's Film Coating Machine Solution not only enhances coating efficiency but also maintains rigorous quality control, all while effectively addressing customer concerns. This solution is suitable for products such as capacitors, inductors, fuel cells, and solar batteries. It excels at precise film tension control during winding and unwinding, reducing tension fluctuations and stretching wrinkles. Moreover, it ensures exceptional precision and uniform coating thickness for better battery quality. Automatic roll replacements eliminate machine downtime, while joint length control reduces waste. In all, Delta's Film Coating Machine Solution has provided the lithium battery industry with a stronger competitive edge.

Building on Delta’s extensive experience in automation, the Film Coating Machine Solution integrates a range of self-developed products. It utilizes the Delta Human Machine Interface to configure parameters and monitor processes. The PC-Based Motion Controller AX-8 Series serves at the core, controlling Delta servo systems and drives. With the open-platform CODESYS, it ensures equipment compatibility with different brands for more flexible electrical system configuration. To ensure coating quality, this solution utilizes the AC Servo Drive & Motor ASDA A3-ET for precise and timely film tension control. The A3-ET conquers computation cycle delays by directly processing tension feedback signals and control functions built within the servo drive, reducing signal processing time. This enhances tension control accuracy and resolves slowdowns from multiple control axes.

Delta’s Film Coating Machine Solution offers the following benefits:
 

• Precise Coating Head Positioning Enhances Manufacturing Quaity
  Achieves coating head positioning accuracy of 0.0001 mm through enhanced PLC programming and manufacturing procedures. Guarantees high-quality uniform film thickness.
• Stabe Tension Control Increases Production Efficiency
  Tension control supported by A3-ET during film winding and unwinding resolves long cycles caused by a high number of axes, thereby elevating overall production efficiency.

• Accelerated Development Cycles
  Smooth CODESYS integration speeds up project development, lowers overall costs, and boosts production efficiency—all of which are crucial factors for thriving in an increasingly competitive market.