Lithium batteries are widely used across various industries due to their high energy density, long lifespan, and lightweight design. However, ensuring their safety and reliability requires sophisticated manufacturing processes, one of the most critical being the battery lamination process.

This process involves applying a protective film to the battery's exterior to safeguard its internal structure and extend its service life. With outstanding stability and precision, Decowell RB Series Expansion I/O modules are the ideal choice for automating and optimizing this key procedure, meeting the stringent control system requirements of lithium battery production.

1. Lithium Battery Coating Overview

The protective film used in lithium batteries is typically made of special plastic materials capable of withstanding external impacts, temperature fluctuations, and humidity. It plays a vital role in preserving the integrity of the internal structure by effectively blocking moisture, oxygen, and other harmful substances, significantly improving battery lifespan and safety.

Moreover, the lamination process involves essential steps such as applying adhesive to overlapping areas of the insulation film, curing the adhesive, and surface activation to enhance adhesion. These procedures improve the insulation performance of the battery, ensuring compliance with safety standards.

2. Challenges in Lithium Battery Coating

Complex Coating Process
A lithium battery lamination line typically includes multiple production stages such as cell preparation, grading, assembly, testing, and packaging. A single lamination section may involve over 2,000 digital signal points. Decowell RB Series I/O modules offer excellent scalability and compatibility, making them well-suited for adapting to complex manufacturing processes.

Precision and Real-Time Control
The accuracy of each lamination layer directly impacts battery performance and safety. Precise control over workstations and temperature is essential during production. Decowell Expansion I/O modules feature a signal response time of less than 4 milliseconds, ensuring every production step is executed with precision.

Stable Communication for Lithium Battery Systems
The lamination process involves high-voltage insulation testing and coordination of multiple servo systems. Strong electromagnetic compatibility (EMC) resistance and a stable communication network are critical to maintaining production efficiency. Decowell RB Series I/O modules meet EMCA-grade protection standards and are ETG conformance certified, ensuring stable system operation and minimal interference.

3. Decowell RB l/O Module Solution

This system utilizes Decowell RB Series Expansion IO modules in combination with distributed remote I/O and servo controllers to optimize the lithium battery lamination process. The main production steps include material picking, film application, short-circuit detection, and discharge. The system also integrates insulation and leakage detection to ensure product quality.

Input Signals Include:

• Start/Stop and emergency stop signals

• Motor positioning (forward/reverse, homing, limit switches, alarms)

• Film material quality inspection

• Short-circuit detection

• Cylinder and sensor position confirmation

Output Signals Include:

• Cell motor forward/reverse control, discharge motor control

• Vacuum solenoid valve control for tape application

• Solenoid valve for short-circuit detection cylinders

The system is built on a Siemens PLC master station, paired with a Decowell RB-1110 Expansion input output for task allocation. This architecture supports dual-line mirrored production, enhancing production efficiency while offering exceptional cost-effectiveness and strong anti-interference performance.

4. Key Features of RB l/0 Modules

• Ultra-thin module design (as slim as 12mm per unit)

• Three-section structure with hot-swappable support for easy on-site maintenance

• Large terminal openings for tool-free wiring

• 45° angled interfaces to reduce connector stress

• Integrated protection features such as overcurrent and reverse polarity protection.

• Powerful diagnostics at both module and channel levels

• DIN35 rail mounting with spring latch design for one-click installation