Related Vendors

Mitsubishi Electronic Europe BV

Taiwan Machine Tool & Accessory Builders' Association (TMBA)

Wuxi InfiMotion Technology Co., Ltd.

The four decisive factors

Using Mitsubishi Electric's AI-driven solution Melsoft MaiLab, they discovered that four factors strongly correlate with variations in layer thickness: voltage, coating pressure, overtemperature, and distance from the coating opening.

Armed with this valuable information, the team developed a diagnostic rule for detecting thickness. They then combined this with industrial automation technology, such as voltage regulators, to carefully monitor and adjust the parameters, ensuring that as much of the strip as possible meets quality standards.

Implementing a digital future

The introduction of tools, technologies, and expertise required for a digital production line is not necessarily a complex procedure. It is also not a binary "all-or-nothing" change that must be implemented in an entire production line at once. It is a change that needs to be approached carefully. A successful implementation requires more than just purchasing the appropriate equipment. It must be approached from two perspectives simultaneously—the technical and the operational.

On the technical side, a manufacturer must have access to the right tools. This means all machines and sensors must have excellent connectivity and be connected to a high-quality data hub using advanced industrial network solutions. Solutions like the CC-Link IE TSN network and Melipc industrial computers can enable highly accurate sampling, which is essential for working with complex and variable materials like lithium-ion batteries.

Unlocking the insights hidden within the data

Moreover, it is important to invest in excellent visualization and correlation tools, such as those included in MaiLab and the Iconics Genesis64 Suite. These allow experts to uncover the insights hidden within the data, and AI-driven algorithms can sift through masses of information to uncover correlations that a human would never have discovered.

With a digital twin tool like Melsoft Gemini from Mitsubishi Electric, manufacturers can create a virtual replica of the process and test any changes. However, it is important not to make a digital twin too complex, especially in the early stages of a company's digital journey. There is little point in modeling an entire factory if one is only interested in a single machine.

Manufacturers should proceed gradually

At an operational level, digitalization in the production of lithium-ion batteries begins with establishing a solid operational foundation, which is essential for harnessing the full potential of new technologies.

Instead of a comprehensive overhaul, manufacturers should proceed incrementally and start pilot projects for specific areas of their operations. These projects serve as practical first steps. They help teams become familiar with the new tools and processes within a manageable scope, address any issues on a smaller scale, and demonstrate the tangible benefits of digitalization.

Achieve quick wins with pilot projects

Pilot projects with clear, measurable goals are a strategic way to achieve quick wins, gain stakeholder buy-in, and pave the way for broader implementation. This methodical approach facilitates the smooth integration of digital manufacturing technologies, reduces risks, and enhances the efficiency and quality of the manufacturing process. By starting small and scaling based on successes, manufacturers can ensure a more effective transition to digital manufacturing, positioning themselves to meet the evolving demands of the battery market.

Turn challenges into opportunities

The lithium-ion battery industry faces incredible opportunities but also significant challenges. Given the rising demand for electric vehicles, expanding production requires not only strategic planning but also leveraging technologies and data to efficiently manage these complex interconnections.

Digitalization offers a clear way forward. It enables real-time monitoring and analysis, improves decision-making and product quality, and simultaneously reduces waste. Transitioning to a digitized manufacturing process requires investment and a shift in mindset but promises tangible results. As the lithium-ion battery industry evolves, digitalization is not just an option for those who want to lead the sustainable energy transition but a necessity.

While digitalization is often obscured by a cloud of jargon and business speak—"Industry 4.0," "smart manufacturing," "Internet of Things," etc.—the reality is simple. The core of digitalization lies in transforming the analog into digital and subsequently applying technical knowledge and expertise to deliver improved and optimized processes.

It doesn't have to be more complicated than that.