The Challenge
In the manufacturing of lithium-ion batteries, every process—from electrode preparation and cell assembly to formation and grading—imposes strict requirements on the equipment’s speed, tension, and precision control. As a core power electronic device capable of motor speed regulation and energy optimization, the inverter can precisely control the motor’s operating state by adjusting the frequency and voltage of the output power supply. It serves not only as a key component and the "power adjustment core" in lithium-ion battery equipment systems (ensuring production efficiency, product quality, and process stability) but also as a critical foundation for guaranteeing the quality, efficiency, and cost control of lithium-ion battery production. Moreover, with the continuous upgrading of lithium-ion battery processes, the inverter will continue to iterate in terms of control precision, integration level, and intelligence, further driving the high-quality development of the lithium-ion battery manufacturing industry.
The Solution
Throughout the entire lithium-ion battery production process, equipment imposes high requirements on speed (e.g., coater speed adjustable from 5 to 20 m/min to match the thickness needs of different electrode sheets), tension (electrode sheet fluctuation ≤ ±3N to avoid wrinkling and stretching), and precision (winding alignment deviation ≤ 0.05mm to prevent cell short circuits). With "precision control, stable adaptation, and energy-efficient operation" as its core, the inverter forms an application solution covering the entire production process.
By means of customized selection (e.g., vector control inverters for front-end mixing to achieve smooth speed regulation from 0 to 1500 r/min; servo-type inverters for mid-end winding to reach a positional accuracy of ±0.01mm), multi-system linkage (real-time interaction with PLCs and tension/temperature sensors via the Profinet protocol to form closed-loop control), and full-lifecycle operation and maintenance, the inverter is integrated into equipment operation. This ensures cell consistency (qualified rate ≥ 99.5%) and stable production (fault downtime rate ≤ 0.1%), reduces costs and saves energy (average energy savings of 15%-30%, with the most significant savings achieved by the rear-end cooling fans), and adapts to process upgrades such as 4680 large cylindrical cells.
The solution adheres to three core principles: process adaptation, environmental resistance (IP54 protection for dusty environments, anti-corrosion coated models for corrosive environments), and system synergy. Broken down by process stages:
For the front-end, corresponding inverters and solutions are selected to ensure uniform and stable electrode sheets;
For the mid-end, specific solutions are used to meet the precise coordination of multiple axes;
For the rear-end, adaptive solutions are adopted to achieve temperature stability and energy savings during idling.
The implementation of the solution covers the entire process, including installation and commissioning (independent or integrated installation selected based on the environment, followed by a 12-hour test run after parameter calibration), operation and maintenance monitoring (establishment of a remote system and cleaning of heat dissipation channels every 3 months), and upgrade optimization. It helps improve the quality, reduce costs, and enhance efficiency of lithium-ion battery production, and serves as a comprehensive full-process solution integrating multiple factors. In the future, the integration of AI and digital twin technologies will better support intelligent manufacturing.