Fully Automatic Pouch Cell Case Forming Machine for Lithium-Ion Battery Production

1. Equipment Overview

1.1 Equipment Functions and Working Principle

■ Equipment Functions:

1.1.1 Servo motor drives manipulator to pull material. Pulling length (700 mm) is precisely adjustable.

1.1.2 Cutter movement is laser-sensor guided. Servo-driven self-adjustment ensures trimming accuracy ± 0.15 mm. (Lead screw covers full cutter stroke, supports cell body length 60 mm – 280 mm)

1.1.3 Stamping section (upper platen driven by 30T booster cylinder to press film; after pressing, 2KW servo motor drives forming core upward to complete pocket forming). Diagram as below:

■ Working Principle:

Speed-regulating motor drives air shaft unwinding. PLC controls servo forming. Servo motor drives manipulator to pull material.

1.1 Equipment Operation Flow

1.2.1 Feeding manipulator clamps material and transfers to designated position based on system settings.

1.2.2 Upon reaching position, 30T booster cylinder drives upper mold to close and maintain pressure. Lower servo motor rises, driving punch to perform deep drawing.

1.2.3 After forming, punch descends. 30T booster cylinder lifts upper mold.

1.2.4 Motor-driven transfer mechanism shifts material by fixed distance.

1.2.5 When material reaches required cutting length, cutter servo moves to position. Cylinder drives cutter downward to cut, ensuring top sealing precision.

1.2.6 Transfer mechanism resets. Next cycle begins.

1.3 Overall Structure

Machine dimensions: L 3200 mm × W 850 mm × H 1980 mm, for reference only.

1.4 Main Components (with diagrams)

1.4.1 Feeding Section

1. Floating roller tension device. Material rollers made of plastic steel.

2. Fiber optic automatic deviation correction for feeding mechanism.

3. Speed-regulating motor for unwinding. Cantilever air shaft holds roll.

4. Red mark sensor before forming section. Prevents case punching to protect mold core.

1.4.2 Stamping Section

1. Power system: upper mold driven by 30T booster cylinder; lower mold driven by servo motor.

2. Stamping motion uses booster cylinder. Software supports two-step forming. Lower servo motor provides ≥40 mm effective stroke, meeting maximum product size forming force requirement (2KW). Equipped with reducer and coupler. Lift plate guided by ball guide column.

Material transfer surface height relative to mold base: 15 – 50 mm.

3. Safety light curtains installed at front and rear of stamping area (mold zone), ensuring no blind spot. Door switches on front and rear mid-section doors ensure personnel safety.

4. Upper mold connected with T60 mm thick 45# steel plate; four sets of Ø40 mm guide columns + linear bearings. (Hole positions to match customer site, compatible with our standard mold mounting holes.)

1.4.3 Pulling Section

1. Servo motor drives pulling mechanism. Uses edge-guided form. Adjustable stroke ≥700 mm.

2. Material pressing unit installed before pulling.

3. Clamping device uses separate cylinder pressing. Clamping block made of anti-slip material.

1.4.4 Cutter Section

1. The cutter is moved up and down via a guide column and sleeve.  
2. The distance between the upper and lower cutters after reset is ≥60 mm.  
3. The entire cutter mechanism is position-adjustable, guided by rails. The adjustable stroke is ≥400 mm, and the effective cutting width is ≥550 mm.  
4. After the pulling process is completed, the cutter moves right to the fixed length (top seal) to cut the last product. It then returns to the previous pocket height. When a pit is detected, the cutter moves another fixed length to cut the waste, ensuring the top sealing accuracy of the previous pocket.  
5. Other requirements:  
5.01 A 30L air tank is to be added.  
5.02 An anti-collision post is to be added, which is interlocked with the equipment. The machine cannot operate unless the post is in position.  
5.03 Maximum mold size: 640 × 550 mm.  
Lower plate hole spacing: L570/400 × W520/420;  
Upper plate hole spacing: L480/320 × W500/400/300/200.

1.4.5 Frame Structure

1. Upper frame: standard aluminum alloy; lower frame: 60 × 60 mm, 4 mm thick square tube welded and spray-coated.

2. All guard doors made of sheet metal (except feeding end). Upper doors have viewing windows. All doors equipped with sensors.

Sheet thickness ≥1.5 mm.

3. All solenoid valves/manifolds equipped with resin mufflers.

4. All pneumatic/electrical cable entries have noise-reduction treatment.

5. Noise at all equipment positions ≤80 dB.

1.4.6 Control Section

1. 65536-color true-color touchscreen.  
2. The HMI must be intuitive and easy to operate, with button sizes designed to prevent double pressing.  
3. The operation panel must include: power ON/OFF, start, stop, and an emergency stop (self-locking type).  
4. All stations must be equipped with manual and single-station operation interfaces, with operations for the same station displayed on the same page.  
5. The touchscreen displays cumulative and shift output for pocket forming and cutting, which can be reset.  
6. In case of a fault, the touchscreen must show complete alarm information and self-diagnostic results, with consistent naming for displayed items.  
7. In manual mode, motion units with logical relationships must be equipped with reliable software interlocks.

1.5 Major Components

1.5.1 Pneumatic components: YSC  
1.5.2 Switches/electrical parts: CHINT  
1.5.3 Sensors: Panasonic / OMRON / KEYENCE  
1.5.4 PLC: Panasonic  
1.5.5 HMI: Delta  
1.5.6 Ball screws/linear guides: TBI / Dinghan  
1.5.7 Motors/drivers: Mitsubishi  
1.5.8 Frame: welded square tube with coating (bottom part); aluminum profile with transparent acrylic (top part)

II. Compatible Incoming Material and Product Specifications

2.1 Incoming Material Dimensions

l Incoming material size specification: Ø350 × 550 mm

2.2 Maximum Formed Product Dimensions

l Maximum formed product dimensions: 560 mm (L, dual-pit) × 550 mm (including air bag W)

2.3 Mold Configuration Compatibility

l The equipment is equipped with one set of integrated mold.

l Mold changeover time: 0.5–1 hour per person.

l Compatible with buyer's existing split-type mold.

III. Equipment Technical Parameters

Item	Description	Specification Requirement
Equipment Function	Yield	First-pass yield: ≥99.5% (excluding defective incoming materials)
	Product Quality Requirement	Servo system repetitive positioning accuracy: ±0.03 mm
	Trimming Accuracy Requirement	±0.15 mm
	PPM	≥5 PPM (one-out-one) (based on baseline cell model C5E2240)
	Machine Failure Rate	≤1%
	Switching time	≤1 hour/person (excluding mold debugging time)
	Incoming material compatibility	Incoming material size specification: Ø350 × 550 mm
Mechanical Section	Machine Overall Dimensions	L 3200 mm × W 850 mm × H 1900 mm
	Machine Weight	Load-to-area ratio < 500 kg/m²
	Main Component Selection	Ball screw / linear guide: TBI / Dinghan
		Cutter mechanism standardized
		Consumables standardized
Electrical Section	Input Voltage and Power	Power 4.5 kW, using 3-phase 380V power supply
	Main Component Selection	Pneumatic components: SMC / AirTAC (SMC preferred, AirTAC for non-critical use)
		Sensors: Daochuan / OMRON / KEYENCE
		Programmable logic controller: Panasonic
		Motor and driver: Mitsubishi
		Switches and electrical components: CHINT
		Touchscreen: Delta
	Electrical Wiring	All wiring, air lines, and tubing must have clear labeling
		PLC must reserve at least 5 I/O ports, and reserve communication ports (Ethernet, RS232, etc.)
	Control System	Provide PLC program source code and touchscreen program source code
		Provide relevant installation software as needed, such as driver software, industrial control cards, etc.

IV. Equipment Installation Requirements

4.1 Equipment Power

Power: 4.5 kW, using three-phase AC 380V power supply.

4.2 Compressed Air

≥0.5 MPa, 20 L/min

4.3 Weight

Total weight (approximately): 800–1500 kg

Load-to-area ratio: ≤500 kg/m²

4.4 Environment Conditions

Room temperature: 10–40°C

Humidity: 30–70%, no condensation

No flammable or corrosive gases.

4.5 Structural Requirement

The overall equipment frame must be solid and movable by forklift.

4.6 Installation Location

Standard workshop