Highly efficient battery production Five tips: Linear guides in battery manufacturing

Related Vendors

Bosch Rexroth Schweiz AG

FAULHABER Drive Systems

Wuxi InfiMotion Technology Co., Ltd.

The production of batteries requires fast, efficient, and repeatable processes. Linear guides play a key role in this, as they must move different loads dynamically and position them precisely. The following tips show how machinery and plant engineering can optimally meet the diverse requirements along the value stream.

1. Resistant materials for dry rooms and electrolyte contact

For the electrolyte and cell production at the beginning of the value stream, the following selection criteria are crucial for linear guides: the materials used must be suitable for dry rooms and withstand the corrosive effects of electrolytes. To prevent plastics in the dry room from becoming porous and prematurely aging due to the highly dehumidified air, Bosch Rexroth uses dry-room suitable materials like polyacetal (POM) or thermoplastic elastomers (TPE) in almost all components, including suitable adhesives, lubricants, and sealants. Guides made with corrosion-resistant materials (NR 2) and hard chrome coatings are also part of the portfolio.

2. Increased productivity through high-performance components

The production of batteries requires highly efficient processes, which means that the linear guides used must also be particularly high-performance. An example is the precise guidance of the spacing regulation in roll-to-roll processes such as calendaring (rolling) or slitting (cutting). The high-performance ball rail systems BSHP from Bosch Rexroth accurately and reliably fulfill such tasks thanks to highly precise rail surfaces and vibration-optimized carriages.

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For short cycle times, Rexroth ball rail guides with belt drive achieve acceleration values of up to 164,04 ft/s² and speeds of up to 16,4 ft/s. Versions with roller and high-speed guide carriages achieve a record-breaking 32,81 ft/s.

In the laser cutting of electrode films for all types of battery cells, the integrated measuring system IMS in the linear guide, combined with linear motors, ensures maximum efficiency with minimal tolerances. The contactless and wear-free measuring process with an integrated decoder in the carriage is insensitive to contamination and achieves repeat accuracy comparable to glass scales, up to ±0.25 µm. The shock and dynamic values correspond to those of the respective underlying linear guide.

3. Cover diverse requirements from a single source

For the various applications along the value stream, Bosch Rexroth offers a finely graded portfolio of linear axes with ball screw or timing belt drive, various types of seals, and accessories. With the complementary linear motor modules, for example, laser welding or contacting machines can be realized compactly and economically.

4. Flexibly usable, combinable, and integrable

Module and pack assembly also benefit from high-performance linear guides, which can be combined into quickly deployable linear axes and Cartesian robots. Compared to industrial robots, linear robots often score higher in precision, dynamics, and compactness due to their mechanical properties. Their range of applications extends from handling, screwing, and dispensing processes to camera transport in end-of-line (EOL) testing.

Selection, design, and configuration are quick and intuitive at Bosch Rexroth through eTools. Pre-installed user software in the Smart Function Kits significantly reduces commissioning and programming time. On this foundation, Bosch Rexroth also creates customized solutions, such as gantry robots for loading, filling, sealing or gluing, screwing, or welding.

5. Find sustainable solutions

Linear technology components and solutions for battery production must also convince in terms of reliability and sustainability. The durable linear guides from Bosch Rexroth implement the required movements with minimal energy loss and lubricant consumption. Maintenance-free applications, flexible interchangeable design, and precise calculation of relubrication intervals up to the total service life contribute to reduced resource consumption.