Fully Automatic Die Cutting Machine for Lithium-Ion Battery Electrodes Sheet Cutting

1. Equipment Overview

1.1 Equipment Function Overview

This equipment is mainly used for cutting cathode and anode sheets (adopting continuous coating process) in the stacking procedure of power lithium-ion batteries.
Electrode rolls are loaded onto the machine's unwinding air shaft either by AGV or manually. The equipment conducts automatic unwinding, and during this process, an automatic edge alignment system corrects the material. Tension is regulated by the tension control system. Before die cutting, a secondary alignment (full web correction) is implemented.
After unwinding and buffering, the tab forming station employs a hardware die to punch and shape the tabs. A CCD system inspects both the front and back sides for defects. Then, the material is pulled to the cutting position by the feeding mechanism. Once cut, the sheets are transported to the finished product tray via a conveyor belt, while defective products are automatically rejected into the NG collection box.

1.2 Action Flow

1.3 Equipment Schematic

1.3.1 Equipment Layout Diagram

1.4 Equipment Highlights

l Unwinding Module: Specially designed air shaft to reduce friction with the roll, enabling quick and easy material change. Automatic unwinding driven by servo motor, using roll diameter algorithm to determine roll usage. When the material is nearly exhausted, the system alarms and stops automatically.

l Feeding Mechanism: Uses patented servo feeding system with ±0.2 mm accuracy.

l Cutting Mechanism: Uses patented non-contact cutting structure, low dust and burrs. The cutter position is adjustable via servo motor according to the sheet size to improve width accuracy.

l Integrated Functions: Optional CCD inspection can be integrated to improve equipment utilization.

l High-Speed Precision Metal Die Punching Mechanism: Servo and eccentric wheel mechanism, fast cutting speed, low noise, stable pressure. Quick die change system with forward/backward, left/right, and angle adjustment. Equipped with independent alignment.

l Tape Bypass Function: When adhesive tape is detected, the cutting knife automatically avoids it, preventing cutter and die damage.

l Die Cooling: Built-in cooling system to reduce blade temperature and prolong die life.

l Precision Granite Cutting Platform: Flatness up to 0.01 mm.

l Stacking Neatness: Servo-driven stacking mode, sheet stacking accuracy ±0.5 mm.

l MES Communication: Two network ports reserved. Hierarchical operation control for convenience.

2. Applicable Incoming Materials and Product Specifications

2.1 Specifications of Applicable Incoming Materials

2.2 Electrode Sheet Die-Cutting Method

2.3 Customer Product Dimension Confirmation Table

2.4 Electrode Sheet Burrs

l Flat burr (Vk, metal burr): ≤10 μm

l Vertical burr (Vh, metal burr): ≤15 μm

3. Technical Specifications

4. Main Components and Functions

4.1 Unwinding Module

l Unwinding direction: clockwise or counterclockwise selectable

l Fiber optic pen assists with alignment during loading

l Equipped with web guiding correction function: accuracy ≤±0.2 mm, stroke ±50 mm

4.2 Splice Table (Taping Station)

- Equipped with a splicing platform and auxiliary marking lines for manual splicing operations  
- Utilizes non-metallic materials; the pressing bar is cylinder-driven with soft contact to prevent damage to electrode sheets  
- A dust collection box is installed under the blade slot, connected to a dust collector via a suction pipe  
- An embedded scale ruler is fitted on the splicing platform

4.3 Tension Control Module

- Swing roller synchronization control: Signals detected by a potentiometer are transmitted to the PLC.  
- Tension control is achieved via PLC + low-friction air cylinder + electric proportional valve.  
- Tension range: 20–100 N; fluctuation during stable operation ≤5%.

4.4 Precision High-Speed Punching Module

- Electrode tabs are shaped using a full precision metal die  
- CCD-enabled automatic web guiding correction ensures consistent punching positions  
- Dual color mark sensors identify front-side tape, allowing for skip punching  
- Safety baffles are fitted to protect operators  
- The die base is made of marble, with a flatness of ≤0.01 mm, ensuring stability and resisting deformation  
- A quick-change tooling system with alignment pins facilitates easy replacement (taking <0.5 hours)  
- Light curtain safety protection is required at the die position  
- Trim scraps are collected in a centralized manner  
- Die punch counts are monitored, with replacement alerts triggered when preset thresholds are met

4.5 Feeding Module (Material Feeding)

l Patented servo feeding system: max speed 60 m/min, accuracy ±0.2 mm

l EPDM rollers used to avoid dust/particles on surface; ensures flat, mark-free electrode sheets

l Upper rollers rubber-coated, 90° hardness, with brush cleaning

l Lower rollers: HV750 hardened chrome-plated steel, Ra≤0.2 μm

l Upper rollers pressed down by air cylinder to ensure dimensional accuracy

l Cutter drive: servo motor + cam mechanism

l Blade material: imported G5 tungsten steel

l Tool change time ≤0.5 h

4.6 Conveyor Belt System

A. Lower Conveyor Belt

l Servo-driven, with electronic cam motion profile for smooth acceleration

l Perforated belt (∅3 mm holes) uses vacuum suction to hold electrode sheets

B. Upper Conveyor Belt

l Servo-driven, electronic cam motion for smooth operation

l 1.5 mm thick perforated belt with vacuum suction, segmented into multiple lanes

l Integrated with discharge mechanism

4.7 Electrode Sheet Collection Unit

l Sheets are automatically stacked into collection box via belt

l Box equipped with auto-lift and full-load alarm

l Buffer unit installed for temporary sheet holding

l Drop stacking precision: ≤±0.5 mm

l No contact between electrode sheet and box wall during drop

l NG sheets removed automatically; with fail-safe alarms: 3 consecutive NGs → alarm; 5 → machine stop

4.8 Double-Side Defect Inspection

l Linear array cameras scan surface while sheet passes over roller, stitching into full image

l Algorithms analyze image features, output OK/NG signal

l NG rejection device removes defective sheets

l Two 4K line scan grayscale cameras + 300 mm high-brightness linear light source

l Detection width: up to 300 mm

l CCD system exports defect data as CSV file

l AI classifies defects by type

4.9 Control System

l Composed of one PLC, one 15-inch touchscreen, and other electrical components

l Bus-style wiring reduces cable volume; clean and organized panel

l Separation of high and low voltage wiring to reduce signal interference

4.10 Machine Frame & Enclosure

l Frame made of high-strength square steel tubes, surface treated by spraying

l Enclosure made of aluminum profile / sheet metal and acrylic for dust protection

5. Main Components List

5.1 Key Components

5.2 Wear Parts List

Production Assembly Plant