Automatic Supercapacitor Cell Casing Machine

Product Overview

This automatic supercapacitor cell casing machine is designed to press welded supercapacitor cells, together with their assembled top covers and O-ring seals, into cylindrical outer cases. The controlled insertion process seats the O-ring securely in the internal sealing position while maintaining consistent casing depth and product alignment.

The equipment is intended for production lines manufacturing 60-series supercapacitors and can accommodate product lengths from 50 to 204 mm. Adjustable insertion depth and product height allow the system to support different cell configurations, while the optional high-frequency heating function is suitable for cases and positive current collectors requiring an interference fit.

Built for demanding manufacturing environments, the unit combines precision guiding, adjustable pneumatic motion, PLC control, electronic light-curtain protection, and a rigid production structure. Stable operation, production counting, and a specified tooling life of more than 500,000 cycles support repeatable output and long-term process control.

Key Features

• Precision Guided Insertion: High-accuracy guide posts and guide sleeves maintain stable movement during casing, helping control alignment and insertion depth from one cycle to the next.

• Adjustable Product Height: The working height can be adjusted to suit supercapacitor products with different dimensions, improving equipment flexibility across multiple production specifications.

• Controlled Insertion Depth: Insertion depth is adjustable, with a depth accuracy of ±0.1 mm. This supports consistent positioning of the cell and O-ring inside the outer case.

• Adjustable Pneumatic Speed: Cylinder speed can be adjusted, with a rated insertion speed of 50 mm/s. Operators can tune motion according to product characteristics and process requirements.

• PLC and HMI Operation: PLC-based control and a human-machine interface provide straightforward operation, status display, parameter adjustment, and convenient production management.

• Integrated Production Counting: The counting function records processed quantities, allowing operators and supervisors to monitor output more efficiently during routine production.

• Electronic Light Curtain Protection: A light-curtain safety system helps protect operators by monitoring the working area and improving operational safety during automatic movement.

• Optional High-Frequency Heating: A high-frequency heating casing option is available for applications where the outer case and positive current collector use an interference-fit assembly method.

• Long-Life Tooling Design: Normal service life of the tooling and mold is specified at more than 500,000 cycles, supporting reduced replacement frequency and dependable production continuity.

• Robust Space-Efficient Construction: The equipment uses a refined geometric design with a compact 700 mm by 500 mm footprint, while the vertical structure provides the working clearance needed for the casing process.

Applications

Technical Specifications

The adjustable insertion depth is a central process-control function. It enables operators to set the casing position according to the product design and maintain the required relationship between the cell, cover, O-ring, and external housing. Combined with precision guide posts and sleeves, this adjustment reduces the risk of inconsistent positioning caused by uncontrolled movement or manual handling.

The pneumatic system is configured for adjustable pressure and speed. An air source of 0.5–0.8 MPa can be adjusted according to the production requirement, while the recommended supply uses dried compressed air at 0.5–0.7 MPa. Dry air helps support stable pneumatic operation and reduces the impact of moisture in the compressed-air circuit. The adjustable cylinder speed allows the insertion motion to be adapted to different casing conditions and product heights.

For production management, PLC control and the human-machine interface provide a practical operating method for industrial users. Operators can work with displayed process information, use the counting function to monitor processed quantity, and manage routine production more conveniently than with a fully manual casing procedure. The stated utilization rate of 98 percent is intended to support reliable scheduling in an automated manufacturing environment.

The high-frequency heating option addresses a specific assembly requirement. When the outer case and positive current collector use an interference-fit structure, heating can be incorporated into the casing process to support the intended assembly method. This option should be evaluated against the product design, material characteristics, and complete process conditions before final equipment configuration.

Installation planning is important because the system has a vertical working height of 2200 mm and a transportation height of 1900 mm. For first-floor installation, the available handling height must be at least 2 m. For upper-floor placement, the elevator should provide a width of at least 1 m, a height of at least 2 m, and a depth greater than 1.3 m. The complete route from outside the factory to the workshop, including access points and the installation method, should be confirmed before delivery.

Why Choose This Product

• Consistent Precision: ±0.1 mm insertion depth accuracy and high-precision guiding support repeatable casing results for production-critical supercapacitor assemblies.

• Designed for Extended Use: Tooling and molds are specified for more than 500,000 normal-use cycles, helping reduce interruptions associated with frequent tooling replacement.

• Flexible Production Configuration: Adjustable product height, insertion depth, pneumatic speed, and optional high-frequency heating allow the system to adapt to multiple assembly requirements.

• Safety and Process Visibility: Electronic light-curtain protection, PLC control, HMI display, and integrated counting provide a safer and more manageable operating environment.

• Practical Industrial Integration: The compact footprint, defined utility requirements, and documented transport conditions make it easier to evaluate installation, factory layout, and line integration before purchase.

Contact us for a quotation, product-size review, or customized casing solution matched to your supercapacitor assembly process.

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