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Electrode Film Edge Guiding for Battery Manufacturing
Challenge: Lithium-ion battery assembly combines rolls of anode, cathode, and separator film into a larger roll of electrode film. Precision edge guiding ensures that these three films are perfectly aligned when moving through steps in the process, such as coating, calendering, and cutting. Poor edge guiding creates waste and compromises quality throughout the process. Detecting small changes in alignment helps prevent costly downtime and scrap by enabling real-time adjustments. To achieve this, a solution is required that can detect slight misalignment in either direction and make automatic adjustments.
Solution: High-Power Fiber Optic Amplifier Paired with a Fiber Array
A high-power fiber optic amplifier like the DF-G3 Series paired with a plastic fiber array, ensures material is aligned correctly by precisely detecting the material’s edge. The fiber optic assembly reliably identifies the edge of the material based on the light intensity resulting from fully or partially blocked beams. If the material blocks half of the beams, the film is centered on the roll and no adjustment is necessary. If the material shifts to the left or right—blocking more or fewer beams and changing the light intensity to a level outside the specified tolerance—the machine uses the real-time sensor data to automatically adjust the roll and realign the material.
The Advantages of Fiber Optic Sensor Technology
Fiber optic systems offer many advantages for edge guiding applications in electric vehicle battery manufacturing. The fibers themselves are small and flexible enough to fit into areas where space is limited: Meanwhile, the optic amplifiers can be mounted in a more convenient location for programming and troubleshooting.
Banner Engineering offers an extensive selection of fiber optic assemblies, along with a wide range of other industrial automation solutions to supplement your edge guiding applications. Banner provides reliable products with global support to help you find the right technology for your application requirements.
Benefits of the DF-G3 Fiber Optic Amplifier
High Pecision and High Power
The high-power amplifier and small core fibers create more intense beams of light for precise position sensing of small parts. These powerful light beams can pick up on slight changes that traditional sensors may miss.
Versitile and Flexible
Pairing the DF-G3 with plastic fibers allows for flexible installation. The versatile plastic fibers are bendable and can fit into a wide variety of spaces. In addition, the DF-G3 amplifiers fit into easy-to-access locations for convenient troubleshooting and maintenance.
DF-G3 Series Long Range Fiber Optic Amplifier
Fiber amplifier with IO-Link capability for detection up to 6 m, precise positioning, and water detection. Output: analog, discrete, dual discrete.