Stacking Machine
Automatic Z-Fold Stacking Machine for Prismatic Lithium Ion Battery Cells
Item Number : DP05
Price varies based on specs and customizations
- Stacking Speed
- 1.0–1.2 s/pcs per station
- Overall Alignment Accuracy
- ±0.3 mm (Adjacent: ±0.2 mm)
- Qualified Product Yield
- ≥ 99%
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Product Overview
This system is an automated, high-precision Z-fold stacking solution engineered specifically for the manufacturing and assembly of prismatic lithium-ion battery cells. Designed to integrate active separator unwinding, secondary electrode alignment, high-speed robotic manipulation, and automated termination taping into a continuous workflow, the equipment ensures consistent layer-by-layer cell matrix formation with minimal cycle times.
Built for advanced energy storage research centers, pilot development facilities, and high-volume commercial cell manufacturing plants, this unit delivers exceptional accuracy across cathode, anode, and continuous separator integration. It eliminates manual handling bottlenecks while safeguarding active battery materials against cross-contamination, physical damage, and geometric misalignment.
Engineered with robust mechanical pinning on all high-speed dynamic axes, integrated electrostatic discharge modules, and comprehensive dust extraction at critical material transfer zones, the machine operates with proven operational stability. It delivers high yield rates and dependable 24/7 uptime under demanding industrial manufacturing conditions.
Key Features
- High-Precision Multi-Axis Stacking: Incorporates dedicated dual-robot pick-and-place mechanisms combined with secondary precision positioning stages, guaranteeing overall electrode sheet alignment accuracy within ±0.3 mm and adjacent sheet alignment within ±0.2 mm.
- Active Separator Control and Static Elimination: Utilizes active motor-driven separator unwinding, integrated tension management, real-time web guiding, and static eliminators to maintain uniform separator tension and achieve edge alignment within ±0.3 mm.
- Advanced Anti-Double-Sheet and Sensor Verification: Features a multi-stage separation system using material box swing airflow, separation brushes, and servo jitter routines, backed by high-frequency ultrasonic sensors to reliably prevent and detect multi-sheet feeding or missed layers.
- Comprehensive Tab and Corner Protection: Outfitted with dedicated independent suction cups for battery tabs alongside automated four-corner optical inspection to prevent tab folding, corner chipping, or damaged active materials from entering the cell core.
- Integrated Contamination and Dust Management: Equipped with high-efficiency vacuum suction at the magazine and secondary positioning stations, non-metallic vacuum wand tips, and physical isolation barriers between cathode and anode magazines to prevent cross-contamination.
- Synchronized Pressing and Smooth Handoff: Features four sets of cross-acting press blades on the stacking platform to secure the layers during high-speed reciprocating movement, followed by robotic core clamping, automated separator cut-off, and integrated termination taping.
- Robust Pin-Locked Drive Architecture: High-speed, high-precision mechanical motion components are secured with precision locating pins to maintain rigid kinematic alignment and resist vibration during continuous multi-shift production.
- Programmable Layer Flexibility: Fully configurable control interface allows operators to freely program the total number of stacked layers within cell thickness limits, creating single-layer outer separator wrap with zero trailing roll waste.
Applications
| Application | Description | Key Benefit |
|---|---|---|
| Prismatic EV Battery Manufacturing | Automated high-speed Z-folding of high-capacity cathode and anode sheets for automotive-grade prismatic lithium-ion power cells. | Maximizes volumetric energy density and ensures strict geometric alignment tolerances across high-volume production. |
| Energy Storage System (ESS) Cell Assembly | Continuous stacking of large-format prismatic battery cells designed for grid-scale, commercial, and industrial energy storage modules. | Delivers layer-to-layer repeatability and consistent interface contact to extend cell life and improve thermal stability. |
| High-Rate Industrial Cell Fabrication | Production of specialty prismatic cells for heavy industrial machinery, marine propulsion, and aerospace backup power systems. | Protects heavy-gauge current collector tabs from bending while maintaining uniform interfacial pressure throughout the stack. |
| Battery R&D and Pilot Line Prototyping | Fast-turnaround cell prototyping for new cathode/anode formulations, solid-state separators, and advanced electrolyte configurations. | Offers fully programmable layer counts and flexible parameter tuning without requiring mechanical tooling changeovers. |
| Consumer Electronics Cell Production | Precision Z-fold fabrication of medium-capacity prismatic cells for high-end power tools, robotics, and commercial electronics. | Prevents active material contamination and corner chipping, maximizing first-pass production yields to 99%. |
Technical Specifications
| Parameter Category | Specification Details (Item Number: DP05) |
|---|---|
| Stacking Speed | Single station: 1.0 – 1.2 s/pcs |
| Auxiliary Handling Time | 10 – 15 s per finished cell core |
| Electrode-to-Separator Alignment | Center deviation: ±0.3 mm |
| Separator End Face Alignment | ±0.3 mm |
| Adjacent Electrode Alignment | ±0.2 mm |
| Overall Electrode Alignment | ±0.3 mm |
| Stacking Layer Configuration | Fully programmable within allowable thickness envelope |
| Outer Separator Wrapping | Single-layer outer wrap, no tail roll |
| First-Pass Product Yield | ≥ 99% (equipment-induced defects only) |
| Equipment Operating Rate (Uptime) | ≥ 98% (equipment-induced downtime only) |
| Supply Power Requirements | Single-Phase AC 220V ±10%, 50 Hz, 4 kW (UK standard plug configuration) |
| Compressed Air Supply | 0.5 – 0.7 MPa (5 – 7 kgf/cm²), Flow Rate: 200 L/min |
| Operating Environment Temperature | 5 – 35 °C |
| Operating Relative Humidity | 5 – 55% RH |
| Ambient Air Quality Standards | Free of conductive dust, corrosive chemicals, toxic vapors, and salt-laden air |
| Vibration & Magnetic Interference | Free of external magnetic fields, mechanical impacts, or perceptible floor vibration |
| Floor Loading Capacity | > 650 kg/m² |
| Machine Physical Dimensions | Approx. W 2350 mm × L 1800 mm × H 2200 mm (subject to final engineering drawing) |
| Total Equipment Weight | Approx. 2500 kg |
| Chassis Finish and Exterior | Industrial Computer Gray |
Why Choose This Product
- Superior Yield Security: Built-in ultrasonic multi-sheet detection, physical magazine isolation, and optical corner inspection eliminate defective feed material, consistently securing a 99% first-pass production yield.
- Precision-Engineered Kinematics: Critical high-velocity axes utilize dedicated alignment dowel pins and non-metallic contact interfaces to prevent mechanical drift, reduce particulate shedding, and sustain ±0.2 mm adjacent alignment.
- Integrated End-to-End Automation: Seamlessly bridges active unrolling, dual-station stacking, precision pressing, separator severing, and adhesive taping into one continuous cycle, boosting overall equipment effectiveness (OEE) above 98%.
- Material-Safe Architecture: Comprehensive vacuum exhaust channels at pick-and-place stages and independent tab manipulators eliminate tab deformation, separator static buildup, and active coating damage.
Contact our battery equipment engineering team today to request a comprehensive technical quotation, evaluate custom tooling configurations, or schedule an in-depth application assessment for your cell fabrication line.
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