Remote IO Optimises Lithium Battery Winding Process

Lithium battery cell manufacturing involves several key steps, including winding, welding, casing, and electrolyte filling. Winding is a critical process that directly affects the battery's performance and quality.

Industry partners trust Decowell Remote IO modules to deliver high precision, speed, and stability in automated battery cell production.

01 Introduction to Cylindrical Cell Winding

The winding process plays a vital role in lithium battery production. In this stage, key materials—such as positive and negative electrode sheets, separators, electrode tabs, protective tape, and end tape—are carefully positioned on their respective feeding shafts. These components are then wound into a battery cell in a precise sequence and direction, requiring a high level of accuracy and stability throughout the production line.

Automating this process not only ensures the winding is completed in a single, seamless step but also minimizes manual handling and reduces the risk of damaging the electrode sheets. This leads to more consistent results and improved overall cell quality.

Welding is another crucial step, where the electrode sheets are joined to the battery casing. The most widely used methods today are laser welding and ultrasonic welding. Laser welding is known for its speed, precision, and minimal heat impact, while ultrasonic welding stands out for its efficiency, low cost, and clean, environmentally friendly operation.

02 Key Challenges in Cell Winding Automation

• Ensuring Speed and Stability

As a mass production process, the core challenge of winding is to maintain high production rates without sacrificing product quality. Faster speeds often risk instability, which can cause defects.

Stable and reliable communication is critical, especially for IO modules. If a module loses connection, the machine stops. Decowell FS series, certified EMC Class A, ensures reliable operation even in demanding environments.

• Increased efficiency of on-site installation

Wiring and cable termination can take up to 30% of machine installation time. Traditional wiring methods are time-consuming and error-prone.

Decowell FS and RS series Integrated IO support E-CON connectors and pre-assembled cables. These piercing terminals eliminate the need for stripping and crimping, significantly reducing wiring time and labor cost.

03 Decowell Remote IO Solution

In this project, Decowell FS series IO modules are used across the winding line for tasks such as ear welding, adhesive application, visual inspection, short circuit detection, and diameter measurement.

The FS modules collect digital signals from sensors and relay outputs to control processes in real-time, helping PLCs accurately execute each production step.

Decowell modules offer fast response, stable communication, and outstanding cost-effectiveness, replacing older, more expensive systems.

• Main PLC: Omron NJ Series

• Application: Cylindrical Cell Winding Process

• IO Configuration: ~800 digital points per line; 23 sets of FS module per machine

04 Decowell Remote IO Features

FS Series Integrated IO Features：

• Supports EtherCAT, PROFINET, DeviceNet, CC-Link, CC-Link IE Field Basic

• Compact size, plug-in terminals, tool-free installation

• Stable communication with zero data loss

• Ideal for logistics, education, standalone equipment, and robotic cells

RS Series Modular IO Features：

• Modular design with hot-swappable functionality

• Mix-and-match modules with short/long base options

• Compatible with multiple signal types and a protective dust cover

• Saves up to 60% panel space with compact layout