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自特斯拉推出4680圓柱電池以來，大圓柱電池就持續(xù)受到行業(yè)高度關(guān)注，深圳中基審時度勢，及時開展4680大圓柱電池的智能高速裝配線研發(fā)，針對大圓柱電池組裝的關(guān)鍵工藝技術(shù)難點，在國內(nèi)率先突破了多項關(guān)鍵技術(shù)。
Since Tesla launched the 4680 cylindrical battery, the large cylindrical battery has continued to receive high attention in the industry. SZJ timely grasped the situation and carried out the development of intelligent high-speed assembly line for 4680 cylindrical batteries. Focusing on the key process and technical difficulties in cylindrical battery assembly, SZJ made a number of key technology breakthroughs domestically for the first time.
 

深圳中基為國內(nèi)B客戶研發(fā)與設(shè)計制造的120PPM 4680高速智能裝配線于2023年7月18日通過客戶驗收。
The 120PPM 4680 high-speed intelligent assembly line developed and designed for domestic B customer by SZJ was accepted by the customer on July 18, 2023.
 
 

作為深圳中基首條交付的120PPM 4680智能高速裝配線，主要包括輥槽&短路測試機、蓋帽焊接機、封口機、氦檢機、密封釘焊接機、清洗機、涂膠機、套膜&二次熱縮機、噴碼機、掃碼裝盤機等設(shè)備。
As the first 120PPM 4680 intelligent high-speed assembly line delivered by SZJ, it mainly includes beading & short circuit testing, cap welding, crimping, helium inspection, tack welding, washing, gluing, sleeving  & 2nd heat shrinking, inkjet printing, barcode scan, cell loading into tray.
 

其搭載了多項自主研發(fā)的革新技術(shù)，使產(chǎn)線具有結(jié)構(gòu)緊湊穩(wěn)定，產(chǎn)品一致性好，效率、良品率和稼動率高，故障率和能耗低等特點，實現(xiàn)全過程自動檢測監(jiān)控和智能化、數(shù)字化生產(chǎn)?？蓮V泛適用于46系列（4680-46120）不同規(guī)格的大圓柱電池，品質(zhì)控制：良率整線>99%，效率實現(xiàn)：產(chǎn)能 ≥120PPM，稼動率≥96%。
It is equipped with a number of independently developed innovative technologies, making the production line compact, stable, with good product consistency, high efficiency, yield and operation rate, and low failure rate and energy consumption. It realizes full-process automatic detection and monitoring as well as intelligent and digitalized production. It can be widely used for 46 series (4680-46120) large cylindrical batteries of different specifications. Quality control: line yield >99%, efficiency: capacity ≥120PPM, operation rate ≥96%.
 


 
輥槽機
Beading Machine
 

設(shè)備主要由電池與托杯分離、輥槽、電池托杯結(jié)合、輥槽上部高度&直徑檢測、電池高度檢查等構(gòu)成。
The equipment mainly consists of battery and cup separation, beading, battery cup combining, beading upper height & diameter detection, battery height inspection, etc.
 

該設(shè)備為凸輪轉(zhuǎn)塔式結(jié)構(gòu)，通過上頂升組件和旋轉(zhuǎn)下壓組件雙邊進給擠壓鋼殼，在鋼殼高速旋轉(zhuǎn)的同時使鋼殼達到一定的形變狀態(tài)。電池雙邊進給、滾刀進給采用凸輪機構(gòu)完成，在保證鋼殼高精度的同時高效完成輥槽。利用基于視覺的高精度飛拍測量技術(shù)，檢測成型的各項尺寸參數(shù)。
The equipment adopts a cam turret structure. Through the upper lifting assembly and the rotating lower pressing assembly, both sides are fed in and squeezed on the steel shell. While the steel shell rotates at high speed, it reaches a certain deformation state. The double-sided feeding of batteries and the feeding of beading blades are completed by the cam mechanism, which efficiently completes the beading while ensuring high precision of the steel shell. The high-precision snapshot measurement technology based on vision is used to detect various dimensional parameters of the formed product.
 

鋼殼口部縮口模具1800萬次    
滾刀1000萬次      
輥槽調(diào)節(jié)范圍：±0.5mm
上部下部加壓調(diào)節(jié)±0.5mm 
Steel shell mouth swagging die: 18 million cycles
Beading blade: 10 million cycles
Beading adjustment range: ±0.5mm
Upper and lower pressing adjustment: ±0.5mm
 
 
蓋帽焊接機
Cap Welding Machine
 

設(shè)備包含電池上料掃碼、正極耳自動找正、蓋帽激光焊接、焊接強度測試、折彎蓋帽、高度檢查以及蓋帽自動上料、激光刻碼等功能。
The equipment includes battery feeding barcode scanning, automatic cathode tab alignment, cap laser welding, welding strength testing, cap bending, height inspection, automatic cap feeding, laser engraving and other functions.
 


該設(shè)備為間歇凸輪式結(jié)構(gòu)，極耳整理時采用光纖傳感器進行位置確認(rèn)，焊接采用振鏡焊接，使焊接效率、精度和位置準(zhǔn)確性高，焊接效果好，配備視覺檢測，檢測極耳焊接后位置的準(zhǔn)確性，防止焊錯位的電池流入下工位，同時通過機構(gòu)與算法相結(jié)合保證電池上料掃碼數(shù)據(jù)與蓋帽激光刻碼數(shù)據(jù)綁定，實現(xiàn)電池的數(shù)據(jù)追蹤。
The equipment adopts an intermittent cam structure. Fiber optic sensors are used for position confirmation during tab alignment. Galvanometer welding is used for welding to achieve high efficiency, precision, position accuracy and good welding effects. Visual detection is equipped to detect the accuracy of tab welding positions After, preventing batteries with incorrect welding from flowing to the next station. At the same time, through the combination of mechanisms and algorithms, it ensures that the battery barcode scanning data during feeding is bound with the cap laser engraving data to achieve battery data tracking.
 

拉力檢測裝置 (0.5 - 1.5㎏f 可自由設(shè)定)
基本延長強度: 2.0㎏f的力下不會拉斷
焊后焊點的CCD檢測精度：±0.05mm
 
Tensile testing device (adjustable from 0.5 - 1.5kgf)
Basic tensile strength: does not break under 2.0kgf force
CCD detection accuracy after welding: ±0.05mm

 
封口機
Crimping Machine
 

設(shè)備由蓋帽高度檢查、DMC清洗、卷邊、蹲封、封口后CCD檢查、內(nèi)阻檢測等構(gòu)成。
The equipment consists of cap height inspection, DMC cleaning, curling, bushing, CCD inspection after crimping, internal resistance detection, etc.
 

該設(shè)備為凸輪轉(zhuǎn)塔式結(jié)構(gòu)，頂桿通過凸輪把電池頂升至封口位，同時封口模具下壓凸輪下降，電池夾具加緊殼體實現(xiàn)殼體封口，運用高精度測量技術(shù)保證封口成型過程的尺寸精確性。實現(xiàn)高精度、高穩(wěn)定性的電池封口。
The equipment adopts a rotary turret continuous cam mechanism. The push rod lifts the battery to the crimping position through the cam, while the crimping die lowering cam lowers, and the battery fixture tightens the shell to achieve shell crimping. High-precision measurement technology is used to ensure dimensional accuracy during the crimping process.  High-precision and high stability battery crimping is achieved.
 

采用超硬合金（G3）
3Jaw≥900萬次    
墩封后外徑精度±0.05mm
Use ultra-hard alloy (G3), 3Jaw≥9 million cycles
Diameter accuracy after bushing ±0.05mm
 
 
密封釘焊接機
Tack Welding Machine
 

設(shè)備用于實現(xiàn)電池的自動上料、激光清洗、上密封蓋、預(yù)焊、激光焊接、CCD檢測等功能。
The equipment is used to achieve automatic battery feeding, laser cleaning, tack loading, pre-welding, laser welding, CCD detection and other functions.



該設(shè)備為間歇凸輪式結(jié)構(gòu)，激光清洗密封釘焊接區(qū)域，保證密封口部清潔的同時不損傷密封圈，密封釘供料采用振動盤供給，有效保護密封釘供給時不會有外部損傷，提高密封釘焊接品質(zhì)。
The equipment adopts an intermittent cam structure. The laser cleans the tack welding area, ensuring a clean sealing mouth without damaging the seal. The tacks are fed using a vibrating disc feeder, which effectively protects the tacks from external damage during feeding and improves the welding quality.
 

焊后CCD檢測精度：±0.05mm
CCD detection accuracy after welding: ±0.05mm

 
套膜&二次熱縮機
Sleeving & 2nd Hot Shrinking Machine

 

該設(shè)備為轉(zhuǎn)盤凸輪式結(jié)構(gòu)，與電池接觸部位使用非金屬材質(zhì)，有效保證電池外觀的完整性，電池通過定量溫度的加熱器和熱風(fēng)區(qū)進行套管熱縮，電池在熱縮過程中電池可自轉(zhuǎn)，保證四周受熱，保證套膜熱縮效果。 
The equipment adopts a rotary turret cam structure. The parts in contact with the battery are made of non-metallic materials, which effectively ensures the integrity of the battery appearance. The battery heat shrinks the sleeve through a quantified temperature heater and hot air zone. During heat shrinking, the battery can rotate by itself to ensure all-around heating and ensure the heat shrinkage effect of the sleeve.
 

套膜裁切精度：±0.15mm
套膜裁切毛刺：≤20μm
面墊沖裁精度：±0.1mm
溫度控制精度：±5°
Sleeve cutting accuracy: ±0.15mm
Sleeve cutting burr: ≤20μm
Pad blanking accuracy: ±0.1mm
Temperature control accuracy: ±5°

 
噴碼機
Inkejet Printing Machine
 

設(shè)備用于電池表面進行噴碼&讀碼。 
The equipment is used for battery surface coding & reading.
 


該設(shè)備為轉(zhuǎn)盤凸輪式結(jié)構(gòu)，電池移送的過程通過凸輪和治具進行限位，在電池勻速運動和位置一致的狀態(tài)下進行噴碼，有效保證噴碼的效果，電池與噴嘴之間距離可通過滑臺進行細(xì)調(diào)，使其達到最佳噴碼距離，電池上料時對其端部進行掃碼，電池掃碼內(nèi)容和噴碼內(nèi)容綁定，實現(xiàn)電池數(shù)據(jù)的追蹤。
The equipment adopts a rotary turret cam structure. The battery transfer process is limited by cams and fixtures to ensure consistent speed and position for coding, effectively ensuring coding quality. The distance between the battery and nozzle can be finely adjusted through the slide to achieve optimal coding distance. When the battery is fed, its end is scanned. The scanned code and spray code of the battery are bound to achieve battery data tracking.
 

電池與噴嘴的移動精度為1-3μm，平行度為7-8μm;
噴碼歪斜≤0.05mm。
The moving accuracy between the battery and nozzle is 1-3μm, the parallelism is 7-8μm;
Coding skew ≤0.05mm.
 

掃碼裝盤機 
Code Scanning and Loading into Tray Machine
 


該設(shè)備為模組輸送帶結(jié)構(gòu)，托盤升降機安裝定位裝置，有效防止托盤傾斜，保證其穩(wěn)定性，電池夾取手指為柔性，下降時有上下浮動功能，有效防止撞機對設(shè)備和電池造成損傷，取料手指具有斷電自鎖功能，防止突然停電時電池下落對電池造成損傷；電池信息與托盤位置通過掃碼綁定，且綁定信息具有唯一性。
The equipment has a module conveyor belt structure with a pallet elevator installed with a positioning device to effectively prevent pallet tilting and ensure stability. The battery gripping fingers are flexible with up and down floating function during descending to effectively prevent collisions from damaging the equipment and batteries. The gripping fingers have power-off self-locking function to prevent battery dropping and damage in case of sudden power failure. The battery information and pallet position are bound by scanning codes, and the binding information is unique.
 

電池定位精度為±0.1mm
Battery positioning accuracy: ±0.1mm
 
   

該產(chǎn)線100%搭載自主研發(fā)的MV Master視覺系統(tǒng)，以全自動在線檢測為核心，采用高精度視覺定位與測量技術(shù)和獨有的視覺缺陷辨識功能，實時數(shù)據(jù)同步上傳，實現(xiàn)智能化生產(chǎn)；在焊機工藝更精準(zhǔn)高效，尺寸管控更加精確的情況下，實時捕捉潛在問題，保障每一道工序的的質(zhì)量穩(wěn)定，賦能產(chǎn)線生產(chǎn)效率及良品率。
 
This production line is 100% equipped with MV Master vision system independently developed by SZJ. With fully automatic online detection as the core, it adopts high-precision vision positioning, measurement technology and unique visual defect identification functions, synchronizes and uploads real-time data to achieve intelligent production. Under more precise, efficient welding process and more accurate size control, it captures potential issues in real time to ensure quality stability in each process, empowering production efficiency and yield of the production line.

 
 
 
 
其中蓋帽焊工序采用單模連續(xù)光纖激光焊接技術(shù)，焊縫上下寬度差小，深寬比大，焊接質(zhì)量好，16個焊點僅需0.3秒，滿足了蓋帽焊超高效率焊接需求。
The cap welding process adopts single mode continuous fiber laser welding technology with small weld seam upper and lower width difference, large depth-to-width ratio, and good welding quality. 16 welding spots only take 0.3 seconds, meeting the requirements for ultra-high efficiency cap welding.
 


密封釘焊接工序采用了自主開發(fā)的高速激光焊接技術(shù)，能量密度高、焊接時間短、熱影響區(qū)小，其焊接速度最可達到70㎜/s，徹底解決了高速線激光焊接的效率問題；上述工藝良率均達到99.9%以上。
The tack welding process adopts the high-speed laser welding technology independently developed by us, with high energy density, short welding time, and small heat affected zone. Its maximum welding speed can reach 70mm/s, which thoroughly solves the efficiency problem of high-speed line laser welding. The yield of the above processes all reach above 99.9%.
 
   
 
圓柱型電池是目前應(yīng)用范圍最廣的鋰電子電池形態(tài)，深圳中基是國內(nèi)最早的鋰電自動化裝配設(shè)備研發(fā)制造商之一。
Cylindrical batteries are currently the most widely used lithium battery form. SZJ is one of the earliest lithium battery automation equipment manufacturers in China to research, develop and manufacture cylindrical assembly equipment.
 
2007年公司自主研發(fā)了25PPM單機設(shè)備。
In 2007, the company has independently developed 25PPM single machine equipment.
 
2008年開始在設(shè)備上運用凸輪結(jié)構(gòu)，使設(shè)備的穩(wěn)定性和效率得到進一步提高。
In 2008, we started to apply cam structures in equipment, the stability and efficiency of the equipment are further improved.
 
2014年自主研發(fā)多工位旋轉(zhuǎn)連續(xù)式的輥槽機，為國內(nèi)首家凸輪轉(zhuǎn)塔式的輥槽機設(shè)備廠商，在封口機上運用了間歇式凸輪傳動技術(shù)，解決了多工位封口穩(wěn)定送料問題，使輥槽以及封口機突破傳統(tǒng)結(jié)構(gòu)，使設(shè)備效率提升至60PPM，同時經(jīng)過多年的凸輪技術(shù)應(yīng)用積累，為后續(xù)的高速凸輪運用技術(shù)打下了堅實的基礎(chǔ)。
In 2014, we independently developed a multi-station rotary continuous beading machine，becoming the first company in China to manufacture rotary turret cam slotting machines. Intermittent cam drive technology is used on the beading machine to solve the problem of stable feeding at multiple crimping stations, breaking through the traditional structures of beading and crimping machines and improving the efficiency to 60PPM.After years of accumulated experience in cam technology application, we have laid a solid foundation for the subsequent application of high-speed cam technology.
 
2015年公司自動化圓柱裝配生產(chǎn)線達到國內(nèi)市場占有率第一，同年公司第一條40PPM26100全極耳電池裝配線成功交付，包含全極耳圓柱電池揉平機、入殼機、多針電阻焊接機、輥槽機、蓋帽焊接機、封口機、噴碼裝盤機等設(shè)備。是國內(nèi)首家研發(fā)使用揉平技術(shù)、入殼技術(shù)、多針電阻焊接技術(shù)、鋼殼輥槽技術(shù)、鋼殼縮口技術(shù)、電池封口技術(shù)等實現(xiàn)全極耳圓柱電池組裝自動化生產(chǎn)。是國內(nèi)最早，最先進，最有實際意義的首條大圓柱自動組裝線產(chǎn)品，奠定了國內(nèi)行業(yè)領(lǐng)先地位，同時推廣到國內(nèi)其他動力電池廠商。 
In 2015, the company's automated cylindrical assembly production lines accounted for the first market share in China. The same year，SZJ successfully delivered a 40PPM 26100 full tab battery assembly line, including full tab cylindrical battery flattening machine, cell insertion machine, multi-pin resistance welding machine, beading machine, cap welding machine, crimping machine, inkjet printing and tray loading machine etc. It is the first domestic company to develop and use flattening technology, casing technology, multi-pin resistance welding technology, steel shell beading technology, steel shell swagging technology, battery crimping technology to realize full tab cylindrical battery automated production. It is the earliest, most advanced and most meaningful first large cylindrical automatic assembly line product in China, which has established a leading position in the domestic industry and has been promoted to other domestic power battery manufacturers.
 
2017年公司完成了國內(nèi)首家小圓柱120PPM高速生產(chǎn)線的突破。
In 2017, the company achieved a breakthrough in the first high-speed small cylindrical 120PPM production line in China.
 
2020年通過公司多年的技術(shù)積累，對轉(zhuǎn)塔凸輪式結(jié)構(gòu)進行改善優(yōu)化，設(shè)備機構(gòu)形式從直線式間歇凸輪運動機構(gòu)，變?yōu)槎喙の恍D(zhuǎn)凸輪連續(xù)式機構(gòu)，動作在圓周運動的過程中通過多工位凸輪機構(gòu)實現(xiàn)，節(jié)約了移栽啟停、動作響應(yīng)反饋的等待時間，轉(zhuǎn)塔凸輪式結(jié)構(gòu)在整個200PPM裝配線上運用，從而使效率從120PPM提升至200PPM。同年，國內(nèi)首創(chuàng)50PPM 40系列大圓柱電池輥槽封口工藝凸輪組裝線研制并交付。
In 2020，Through years of technology accumulation and improvements to the rotary turret cam structure, the equipment structurel form has evolved from a linear intermittent cam motion mechanism to a multi-station rotary continuous cam mechanism, with the actions achieved through multi-station cam mechanisms during circular motion, saving the waiting time for transplanting start-stop and motion response feedback. The rotary turret cam structure is applied throughout the entire 200PPM assembly line, improving the efficiency from 120PPM to 200PPM.The same year，SZJ has developed and delivered the first domestic 50PPM 40-series large cylindrical battery beading & crimping cam assembly line, with innovative beading & crimping process for large cylindrical batteries.
 
2021年國內(nèi)首創(chuàng)25PPM 60系列大圓柱電池激光穿透焊封口工藝凸輪組裝線成功交付。
In 2021, SZJ successfully delivered the first domestic 25PPM 60-series large cylindrical battery laser penetration welding sealing cam assembly line with innovative laser penetration welding sealing process.
 
2022年國內(nèi)首創(chuàng)150PPM 46系列大圓柱電池激光穿透焊封口工藝凸輪轉(zhuǎn)塔高速組裝線單機研制成功，保證電芯入殼時無損傷，效率150PPM，良率99.8%，極耳焊接效率達到0.5S/PCS，良率99.8%，極耳揉平成型效率可以達到150PPM、良率99.8%，包膠效率可達150PPM、良率99.8% 。同時為國內(nèi)龍頭電池廠商提供了各類裝配線解決方案，研制各系列實驗設(shè)備。
In 2022, SZJ successfully developed the first domestic 150PPM 46-series high-speed rotary tower cam assembly line with innovative laser penetration welding sealing process for large cylindrical batteries, ensuring no damage to the cells during cell insertion at an efficiency of 150PPM and a yield rate of 99.8%. The tab welding efficiency reached 0.5S/PCS with a yield rate of 99.8%. The tab flattening efficiency reached 150PPM with a yield rate of 99.8%. The tape wrapping efficiency reached 150PPM with a yield rate of 99.8%. At the same time, SZJ has provided various assembly line solutions for domestic leading battery manufacturers and developed experimental equipment for various series.
 
2023年120PPM4680大圓柱裝配線成功交付。
In 2023, a 120PPM 4680 large cylindrical assembly line was successfully delivered.
 

目前公司已成功研制300PPM圓柱裝配線、交付120PPM 4680大圓柱裝配線，為后續(xù)的批量交付和研制更高效的圓柱裝配線奠定了堅實的基礎(chǔ)！
The company has successfully developed 300PPM cylindrical assembly lines and delivered 120PPM 4680 large cylindrical assembly lines, laying a solid foundation for subsequent mass deliveries and developing even more efficient cylindrical assembly lines!