Cylindrical Battery Semi Automatic Winding Machine for Precision Lithium Ion Cell Assembly

Product Overview

This semi-automatic winding machine is engineered specifically for the precision assembly of cylindrical lithium-ion battery jelly rolls. Designed to bridge the gap between benchtop R&D and high-volume industrial automation, the equipment streamlines the core winding process by combining operator-guided electrode loading with fully automated winding, needle retraction, termination taping, and cell unloading. Its robust mechanical architecture ensures that positive and negative electrode sheets are interleaved with dual separator layers under tightly controlled tension, preventing electrode damage and internal short circuits.

Ideal for battery research institutions, pilot-scale production lines, and specialized cell manufacturing facilities, the system accommodates diverse cylindrical form factors. The equipment provides exceptional operational flexibility, allowing engineers to fine-tune winding speeds, tension profiles, and tape application positions to match varying cathode and anode chemistries, solid-state separator materials, and tab configurations. This adaptability makes it an essential asset for prototyping next-generation cylindrical power and energy cells.

Built with industrial-grade motion control hardware and high-precision tooling, the machine delivers exceptional repeatability and structural reliability during continuous operation. The integrated servo drive system, proximity sensor-based tension control, and active dust elimination systems work synchronously to produce uniform, tightly wound cylindrical jelly rolls free from core deformation, layer slippage, or electrode misalignment. This rigorous design philosophy guarantees consistent electrical performance and high safety standards in downstream cell assembly.

Key Features

• Precision Single-Pin Counter-Piercing Needle Mechanism: Features a rigid, wear-resistant winding pin assembly (Ø6 mm to Ø10 mm configurable) that ensures axial concentricity, stable rotational torque, and clean mechanical disengagement without distorting the internal core of the jelly roll.
• Semi-Automated Operational Workflow: Combines manual electrode insertion with automated high-speed winding, automatic pin extraction, automatic termination tape application, and automatic finished core ejection to maximize throughput while minimizing human error.
• Transverse Termination Taping System: Applies termination tape perpendicularly across the jelly roll and tab structure, achieving flat, bubble-free adhesion and precise positional accuracy without exerting excessive tensile stress on the wound electrode layers.
• Programmable Variable Winding Speed: Driven by a high-performance Panasonic servo motor, the rotational winding profile is fully adjustable through the touchscreen interface to optimize cycle times across fragile, ultra-thin, or thick-coated electrode foils.
• Active Dual-Separator Tension Regulation: Employs independent active unwinding stations equipped with proximity switch sensors and stepping motor controls to continuously and smoothly modulate web tension throughout the entire winding cycle.
• Integrated Electrode Dust Removal Device: Features built-in particle extraction cleaning assemblies at the electrode feed interfaces to eliminate slitting burrs and loose active material debris before winding, significantly reducing cell self-discharge and micro-short risks.
• Automated Separator Outer-Wrap Finishing: Automatically wraps and cuts the protective outer separator layer to standard specifications, ensuring full dielectric encapsulation of the active electrode stack prior to tape bonding.
• Anti-Defect Winding Architecture: Engineered kinematic alignment prevents common fabrication defects such as separator tearing, core telescoping, layer slippage, and edge overhang, yielding pristine cylindrical jelly rolls ready for can insertion.
• Rapid Tooling and Format Changeover: Designed with modular guides, quick-release clamps, and intuitive digital parameter storage to enable swift retooling between different cylindrical cell dimensions and pin sizes with minimal downtime.
• Intelligent PLC and True-Color HMI Control: Governed by an industrial Panasonic PLC paired with a 7-inch MCGS high-resolution touchscreen, providing real-time diagnostics, recipe management, built-in fault alarms, and a one-touch system reset.

Applications

Technical Specifications

Why Choose This Product

• Superior Geometric Consistency: Engineered with rigid structural frames and servo-driven counter-piercing pins, this winding system prevents core runout and electrode telescoping, ensuring perfectly square jelly-roll ends for predictable cell canning.
• Active Web Tension Stability: Unlike passive friction-brake winders that cause separator necking or slack, the active stepping-motor and proximity-sensing tension system continuously balances web dynamics across changing reel diameters.
• Contamination-Free Cell Construction: Integrated dust removal assemblies clean electrode surfaces at the insertion point, eliminating metallic particles and slitting burrs that degrade cell cycle life and cause catastrophic internal shorts.
• High Return on Investment for Pilot Lines: Offering automated winding, taping, and unloading in a compact semi-automatic footprint, this system minimizes labor dependency while maintaining the agile flexibility demanded by modern battery labs.
• Tier-One Component Reliability: Built exclusively with premium industrial automation components—including Panasonic servo drives, Leadshine stepper actuators, and AirTAC pneumatics—ensuring 24/7 operational durability and worldwide parts availability.

Contact our technical engineering team today to request a quotation or discuss customized tooling and needle configurations tailored to your cylindrical battery assembly requirements.

Trusted by Industry Leaders