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Challenges facing lithium-ion battery manufacturers

In the global effort to meet the evolving needs of electrochemical energy storage solutions, lithium-ion batteries continue to stand out as the most advanced technology in the battery ecosystem.
At the same time, demand for batteries of the next generation is growing consistently, with an emphasis on safety, affordability, and higher energy density. In order to achieve this, battery manufacturers face challenges at many stages of battery development.

We have got you covered!

Mitsubishi Electric knows first-hand everything about coating, calendering, trimming, winding and stacking issues, as well as quality detection. We know how these elements can be combined with data collection instruments and communication protocols in building the digital twin of the battery manufacturing chain.

As a company, we have been successfully supporting lithium-ion battery manufacturers to improve their production processes in terms of quality and efficiency (natural resources and energy consumption, cost, operations etc.). We know that the key to successfully addressing these challenges lies in the digitalisation of production.

years’ experience in supporting lithium-ion battery module/pack manufacturing
customers all over the world

Our complete solution and application support contribute to improved quality and increased productivity for many kinds of manufacturing equipment.

Line speed stabilisation Tension stabilisation Improving coating thickness accuracy Reducing setup time
Stable drive of large-inertia rolls Preventing synchronisation loss between roll presses Stable tension control
Improving shape and slit position accuracy Efficient energy usage Improving tension stability on acceleration
Stabilising line for non-round winding shafts Improving accuracy for electrode cutting length Improving tension stability for sudden acceleration
Increase in synchronised drive shafts Speeding up stacking operation and improving separator tension fluctuation Correction of position errors between separators and electrodes
Easy sharing of data between devices Supporting various process configurations while standardizing equipment Sending large volumes of test data to upper-level systems in real time
Easy sharing of data between devices Standardize equipment while accommodating various process configurations

What is the key to successful digitalisation?

Digitalisation requires scalability, performance, and skills to create value. This process relies on the effective use of data at multiple levels.

Transformative gains in lithium-ion battery manufacturing through digitalisation

Increased productivity

The use of digital technologies allows monitoring and optimisation of production processes, which contributes to increased battery production efficiency.

More accurate quality control

Digital control and analysis of data collected from production processes enables detection of defects and quality deviations at earlier stages, leading to improved quality of final products.

Reduced production time

By controlling processes more closely and optimising production layouts, battery production times can be reduced.

Optimising energy consumption

Data analysis can identify areas where energy can be saved.

Predictive maintenance

The data collected enables prediction of the moments when machines or equipment are likely to fail, enabling maintenance planning and minimising downtime.

Innovation in design

Digital design tools allow for more efficient and advanced battery designs, which can improve battery performance and durability.

Close process monitoring

The sensitivity of the lithium-ion battery manufacturing process requires continuous and accurate monitoring in a real-time system, which digitalisation provides.

Integration of research processes

Digitalisation makes it easier to track research and development processes, which enables more efficient implementation of new technologies and materials.

More information on Lithium-ion battery production

White paper - Lithium-Ion Battery

Lithium-ion battery manufacture is a demanding application environment, with pressure to increase yield and reduce waste while at the same time driving up the speed of production. And with rapid market growth on a global scale, manufacturers need to explore new avenues to gain a competitive advantage.

Data holds the key, but while data availability is huge, traditional monitoring of machine overview data is no longer sufficient to drive the productivity gains that are required. This paper examines how we can dig deeper for genuine insights in the operation.

Please register below to download the Whitepaper!

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Software Solutions Line-up

Mitsubishi Electric’s Data Science Tool MELSOFT MaiLab is a data science tool that further improves manufacturing by replacing “human experience and intuition” with digital technology and enabling it to be easily incorporated into control systems.
MELSOFT VIXIO software utilizes high-speed, high-accuracy AI to enable quick detection of defective products. The intuitive software allows making AI models for your products, without the need of specialized knowledge in AI or programming.
Pre-verification is performed in the digital space of a virtual factory or equipment line. This significantly reduces cost and time during the design phase.
Next Generation in HMI/SCADA Automation Software

Product Line-up

Creare nuovi valori con MELSERVO J5.
Motion controllers ad alte prestazioni per la piattaforma iQ.
Controllori per servosistemi per PLC della serie MELSEC iQ-F.
High-speed line scan bars for print/quality inspections and surface scanning
Controls the tension during unwinding/rewinding of long materials