Metal Pass Lithium Battery Industry 4.0 System

The development of lithium battery Smart Manufacturing began in early 2012. Through the development of a large number of models and intelligent systems, a complete defect early warning system and other technologies have been formed.

High Accuracy of Metal Pass Burr Defect Model: A Case of A Large Lithium Battery Factory

Burr defect is the main trigger factor of lithium battery fire (such as Samsung mobile phone lithium battery explosion last year); In order to track and warn the burr defect size of lithium battery electrode on line, Metal Pass team established a burr defect size prediction model for a large lithium battery factory, and defined the accuracy of the model prediction by comparing the predicted value of the model with the actual measured value.
At the beginning of cooperation: the factory strictly inspected the level of Metal Pass model with this pole slice slitting burr prediction model, which is very difficult to model. It is required that the hit rate of the model is 85%, and the hit rate of Metal Pass "brain" is 98%; When this result is incredible, another batch of data is measured again, and the hit rate of Metal Pass model is higher; At present, the second phase of burr expectation project has successfully applied the extremely difficult soft sensing technology in the industry in view of the current situation of weak data acquisition ability of China's manufacturing industry; Soft sensing is to predict the parameters to be measured by using high-precision model when it is difficult to measure directly.
After the first stage of running in: the second stage of the project will further predict the failure of cutting tools and burr defects, and use software to realize the online early warning and tracking of the size of defective products, so as to ensure that defective products do not occur or reduce defective products (defective products are when the size of defects exceeds the maximum allowable value).
According to the evaluation of the project cooperation within the factory: at present, only Metal Pass can provide this process / product model system combining equipment and automation.  

Metal Pass Lithium Battery Industry 4.0 System

In the manufacturing process of lithium battery, there are dozens of manufacturing sections in the production of lithium battery itself. In the process of lithium battery production, a variety of intelligent systems are needed, such as slurry preparation Level 2, tablet pressing (rolling) Level 2, slurry drawing (coating) Level 2, winding Level 2 and volume distribution Level 2 system, etc.

This example is a two-stage system of tablet pressing (rolling), which is divided into four parts, and each part contains many items.

I: Total system technology

1. Metal Pass industry 4.0 system: including online order system and Metal Pass intelligent system

2. Metal Pass three-level computer system: three-level automation at the workshop level includes primary system basic automation, Level 2 model and logic, and tertiary system manufacturing execution system MES

3. Metal Pass lithium battery quality package: deal with dozens of common defects in various sections of the lithium battery manufacturing process

4. Technology development based on Metal Pass intelligent system: Based on the existing technology development platform of more than 100 sets of lithium battery models and more than 100 sets of other traditional industry models, it has 3 million won programs and dozens of common business fields

5. Application case - pole piece manufacturing similar projects: it has similar sections such as slurry, coating, baking, rolling, slitting and so on, which are very similar to the manufacturing of lithium battery pole pieces. There are completed intelligent systems in this similar field

6. Application case of Level 2 - Cascade steel (USA): including electric furnace, electrostatic furnace and continuous casting intelligent system similar to incoming material processing, sauce mixing and other links

7. Lithium battery system development plan - refer to similar projects completed: refer to a large number of intelligent system projects completed earlier

8. Customized development of lithium battery system - completed model framework: more than 100 sets of models have been completed in the fields of slurry, coating, rolling, baking, slitting and winding

9. Existing resources for the development of tablet pressing Level 2 system: various resources collected all over the world, especially a large number of documents of rolling Level 2 system.

II: Customized process model (phase I)

1. Basic model list: list of dozens of related models

2. Main measurement parameters: the measurement parameters that need to be measured directly or obtained from the manufacturing execution system

3. Calculation of roll thermal crown: in order to achieve flat roll gap and eliminate elastic bending, the roll is engraved with crown, and the diameter in the middle of the roll is greater than that on both sides

4. Roll wear die model: with the roll pressing, the roll is wearing, so the roll is divided into geometry? Wear should be considered

5. Good conditions for polar plate crown model and shape (initial setting): roll crown, roll spring, roll thermal expansion, roll wear and other comprehensive effects shall make the roll gap straight

6. Thickness of pole piece: it depends on the roll gap, tablet pressing force and equipment rigidity: the roll machine frame has elastic deformation and negotiation, and the thickness of pole piece shall be obtained through comprehensive calculation

7. Several different relationship equations between the thickness of pole piece and the value of roll gap: the relevant model considers elastic deformation, etc

8. Roll temperature control model: considering the influence of thermal expansion on roll diameter

9. Heat transfer model of rolling zone: the temperature at the roller bearing is high, and the relevant heat transfer shall be calculated in other places; When high-temperature oil is used inside the roll, the thermal expansion and heat transfer shall be calculated

10. Temperature rise due to friction: temperature rise due to roller friction

11. Temperature change of pole plate caused by heat conduction: temperature calculation based on heat transfer and finite difference method

12. Tablet pressing force model: the Opium force is composed of the impurity pole piece body and pole piece butcher medium

13. Model development time plan: the development can be completed in more than three months

III: Quality closed loop control (phase II)

1. Significance and acceptance objectives of quality closed-loop control project: when the objectives of closed-loop control are input into the system, the system will automatically adjust various parameters to finally achieve the required objectives, such as thickness

2. Overall demand for online control of tablet pressing process: various influences required by online control room

3. Closed loop control: the thickness of the pole piece is consistent along the width: the material of the pole piece needs to be consistent in thickness and strength

4. Process parameter matching requirements: considering the mutual compensation of various parameters, including various process problems, problem description and solutions, etc

5. Matching requirements of process parameters: speed, temperature, acceleration, etc

6. Equipment parameter matching requirements: various size parameters and operation parameters of the equipment

7. Requirements for product quality parameters: quality requirements for ductility, microporous structure, surface compactness, flatness and rebound performance

8. Closed loop control system (example: thickness consistency): the thickness of the key is consistent along the width direction, and it is not expected to be thick in the middle, thin on both sides or thick on both sides

9. Existing closed-loop control project cases: existing project cases

10. Closed loop control development time plan: about more than three months

IV: System software development (phase III)

The development of software is based on the development platform, taking into account various customization models.

1. System functions and acceptance objectives in the Level 2 system development stage: the functions that the Level 2 system should achieve in each stage

2. Overall functions of the Level 2: quality requirements, various actuaries, process simulation, best strategies, self-study, constraints, man-machine interface and network, etc

3. Calculation and self-study process: after machine learning the model according to the online data, the model is fully bound with the corresponding production line, that is, the model is extremely accurate

4. Recalculation: on the basis of some estimated calculations, make another calculation according to the existing measured data. For example, the actual thickness may be different from the pre estimation, as well as the temperature, which is difficult to estimate correctly earlier

5. Recalculation trigger type:

6. Recalculation processing steps:

7. Process simulation, strategy calculation and self adaptation: the intelligent system has the function of process simulation. It can be assumed that the whole production process is running, but the equipment is not running. Because the intelligent system uses online data with high accuracy, the effect of mold locking process simulation is basically the same as that of actual production

8. Production policy calculation: Calculation of production policy group parameters

9. Factory task setting:

10. Limiting factors of production setting calculation:

11. interface

12. data storage

13. Hardware configuration

14. Interface between Level 2 and other systems:

15. Level 2 (L2) related network structure: in 4G network, the correlation among primary, Level 2 and tertiary systems

Tech & Products

   Situation, Metauniverse, 4.0 brains, Smart manug, Equipment Softw.
   Defect warning, Defect detection, Li-battery, Level 2 platform

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