Stacking Machine
Semi Automatic Lithium Ion Battery Z Fold Stacking Machine for Prismatic and Pouch Cell Stacking
Item Number : DP06
Price varies based on specs and customizations
- Stacking Cycle Speed
- 1.3 – 1.6 s/pcs
- Adjacent Electrode Alignment Accuracy
- ±0.2 mm
- Compatible Finished Cell Thickness
- 5 – 20 mm
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Product Overview
This semi-automatic Z-fold stacking system is engineered specifically for the precision assembly of prismatic and pouch-type lithium-ion battery cells. Designed to execute continuous Z-pattern separator folding while alternating the placement of positive and negative electrode sheets, the equipment combines servo-driven mechanical handling with active web guiding to maintain micron-grade alignment across all cell layers.
Optimized for pilot-scale manufacturing, prototyping facilities, and advanced energy storage research laboratories, this stacking platform accommodates a broad spectrum of cathode and anode sheet geometries. By automating the pick-and-place cycle, secondary alignment, and separator tensioning, the system eliminates the human variability typically associated with manual stacking operations while maintaining flexible batch changeover capabilities.
Constructed on a heavy-duty, vibration-damped structural baseplate and enclosed within a rigid protective framework, this equipment delivers an equipment-caused pass rate of 99% and an operational uptime rate of 98%. It provides consistent repeatability, preventing electrode scratching, separator misalignment, and multi-sheet feeding during rigorous long-shift research and pre-production workflows.
Key Features
- Micro-Lift Presser Knife Buffering: The four-knife stacking mechanism features an engineered micro-lift sequence that slightly raises the blade before lateral retraction, preventing friction-induced scratching, coating delamination, or tearing on fragile active material surfaces.
- Active Separator Unwinding with Web Guiding: An integrated motor-driven payoff reel combines with a floating dancer roller tensioner and edge-position correction (EPC) system, maintaining uniform web tension and an edge alignment accuracy of ±0.3 mm throughout the Z-fold cycle.
- High-Precision Secondary Positioning: Dedicated pneumatic alignment stages re-index each electrode sheet before transfer to the stacking platform, achieving adjacent electrode registration accuracy within ±0.2 mm and total layer alignment within ±0.3 mm.
- Multi-Stage Anti-Double-Sheet Feeding: The material feeding magazines integrate compressed air blowers, specialized separator brushes, and high-frequency robotic vacuum manipulator shaking to prevent multi-sheet pick-up and missed feeds.
- Integrated Dust Collection Architecture: Localized vacuum extraction ports are engineered directly into the magazine cassettes and secondary positioning stages, instantly capturing loose particulates and slitting debris to prevent internal cell shorts.
- Servo-Driven Manipulator Architecture: A high-torque servo motor and ground precision ball screw assembly drive the four-gripper pick-and-place manipulator, ensuring rapid, smooth, and jerk-free electrode transfer across operating cycles.
- Thermal Resistance Wire Separator Cutting: Upon completing the programmed layer count, the system executes a clean, rapid cut of the continuous separator web using a precision-controlled heating element, preventing frayed edges and particulate generation.
- Intuitive Touchscreen HMI and PLC Control: A centralized programmable logic controller paired with an industrial color touchscreen interface provides comprehensive recipe management, real-time diagnostic telemetry, layer count configuration, and dynamic parameter tuning.
Applications
| Application | Description | Key Benefit |
|---|---|---|
| Prismatic Lithium-Ion Battery R&D | Precision Z-folding of alternating cathode and anode sheets for high-energy-density prismatic power cells. | Eliminates internal short risks through ±0.2 mm adjacent electrode alignment and micro-lift knife buffering. |
| Pouch Cell Pilot Line Manufacturing | Semi-automated batch stacking for electric vehicle (EV) and energy storage system (ESS) pouch cell prototyping. | Delivers high cycle throughput (1.3–1.6 s/pcs) with minimal tooling changeover time between cell dimensions. |
| Solid-State and Advanced Cell Development | Stacking of brittle or ultra-thin ceramic-coated separators and advanced dry-process or wet-coated electrodes. | Gentle vacuum manipulation and dancer-controlled web tension preserve fragile experimental active layers. |
| Sodium-Ion Battery Assembly | Assembly of alternative chemistry cells requiring precise tension control and strict particulate-free processing. | Multi-point dust extraction modules prevent cross-contamination and conductive debris build-up. |
| Academic & Industrial Battery Labs | Flexible small-to-medium batch cell assembly across varied electrode dimensions (80–200 mm length). | User-friendly PLC interface allows rapid layer reconfiguration and material testing without hardware modifications. |
Technical Specifications
Machine Overview & Identification
| Specification Parameter | Value / Detail |
|---|---|
| Product Item Number | DP06 |
| Stacking Technology | Semi-Automatic Z-Fold Continuous Separator Stacking |
| Stacking Speed | 1.3 – 1.6 seconds per piece (electrode sheet) |
| Auxiliary Handling Time | 15 – 20 seconds (cell transfer and reset) |
| Equipment Pass Rate | 99% (defects attributable strictly to machine operation) |
| Equipment Operating Rate (Uptime) | 98% (faults attributable strictly to machine operation) |
| Total Rated Power | 2.0 kW |
| Control Architecture | Industrial PLC with Full-Color Touchscreen HMI |
Stacking & Alignment Tolerances
| Alignment Metric | Tolerance Specification |
|---|---|
| Electrode-to-Separator Center Deviation | ±0.4 mm |
| Separator End-Face Alignment Accuracy | ±0.3 mm |
| Adjacent Electrode Sheet Alignment Accuracy | ±0.2 mm |
| Overall Finished Electrode Stacking Accuracy | ±0.3 mm |
| Separator Serpentine Web Error | < 1.0 mm / 1000 mm |
| Electrode Die-Cutting Tolerance Requirement | < 0.2 mm |
Incoming Material Dimensions
| Material Type | Length (mm) | Width (mm) | Thickness (mm) | Core / Roll Dimensions |
|---|---|---|---|---|
| Cathode & Anode Sheets | 80 – 200 mm | 80 – 150 mm | 0.07 – 0.25 mm | Sheet material (die-cut, flat) |
| Electrode Tabs | 8 – 20 mm (Tab extension) | 8 – 20 mm (Tab width) | — | Same-side tab orientation |
| Separator Web | Continuous roll | 80 – 155 mm | 0.02 – 0.04 mm | Inner: φ76.2 mm (3"), Max Outer: φ300 mm |
Finished Cell Envelope Capabilities
| Cell Parameter | Dimension Range / Specification |
|---|---|
| Finished Cell Thickness (H) | 5 – 20 mm |
| Finished Cell Width (W) | 80 – 150 mm |
| Finished Cell Length (L) | 80 – 200 mm (excluding tab extension) |
| Tab Length Extension (Q) | ≤ 20 mm |
| Tab Width | ≤ 20 mm |
| Outer Separator Wrapping | Automated blank fold reserve; manual tail wrap and tape application |
| Stacking Layer Capacity | Programmable within the 5–20 mm cell thickness envelope |
Functional Hardware Subsystems
| Subsystem Module | Quantity | Engineering Functionality & Features |
|---|---|---|
| Stacking Platform Mechanism | 1 Set | Four sets of presser knives with crossing action and micro-lift buffering. |
| Robotic Manipulator Assembly | 1 Set | Servo motor and ground ball screw driving a 4-gripper pick-and-place transfer head. |
| Separator Payoff & Web Guiding | 1 Set | Active motor unwinding, floating dancer roller tension control, and dynamic EPC edge tracking. |
| Secondary Positioning Stations | 2 Sets | Pneumatic push-gauge alignment blocks with integrated dust collection nozzles. |
| Electrode Magazine Cassettes | 2 Sets | Magazine-style auto-elevating cartridges with constant height tracking, air knives, and separation brushes. |
| Separator Cutting Unit | 1 Set | Controlled electric resistance heating wire for clean thermal cut-off. |
| Cell Unloading Mechanism | 1 Set | Pneumatic clamp manipulator transferring stacked cores to the manual taping station. |
| Chassis & Structural Frame | 4 Units | Heavy-duty dual main frame and precision ground sub-baseplates for vibration isolation. |
| Enclosure & Safety System | 1 Set | Industrial aluminum profile safety canopy with interlocked transparent access panels. |
| Vacuum System | 1 Set | High-flow compressed air-driven vacuum ejector network for multi-cup pick heads. |
Facility & Operating Environment Requirements
| Utility / Environmental Parameter | Operating Standard |
|---|---|
| Input Electrical Supply | AC 220V Single-Phase, 50/60 Hz (Voltage fluctuation within ±10%) |
| Pneumatic Supply Pressure | 0.5 – 0.7 MPa (5 – 7 kgf/cm²) |
| Compressed Air Consumption | 100 L/min |
| Physical Dimensions | 1550 mm (W) x 1250 mm (L) x 1850 mm (H) |
| Net Machine Weight / Floor Load | Approx. 800 kg / Floor load capacity > 450 kg/m² |
| Ambient Operating Temperature | 5 – 35 °C |
| Operating Relative Humidity | 5 – 55% RH (Non-condensing) |
| Atmospheric Cleanliness | Free from conductive dust, corrosive chemicals, toxic vapors, and salt-laden air |
| Vibration & Magnetic Interference | Isolation from external high-magnitude magnetic fields and structural shock/vibration |
Why Choose This Product
- Superior Cell Geometry Control: High-precision secondary pneumatic positioning paired with active web guide tracking ensures strict dimensional repeatability (±0.2 mm adjacent sheet alignment), directly translating to higher electrochemical performance and lower internal impedance in finished cells.
- Active Surface Protection Architecture: The synchronized micro-lift mechanism raises presser knives before lateral withdrawal, safeguarding delicate cathode and anode active material coatings against shear-induced micro-scratches, pinholes, and particle shedding.
- Integrated Contamination Management: Dual-station dust collection ports coupled with air-knife de-nesting and separation brushes eliminate conductive dust build-up and multi-sheet misfeeds, ensuring a 99% baseline production yield.
- Rugged Industrial Reliability: Fabricated from heavy-duty structural steel and rigid aluminum tooling plates, this unit delivers a 98% operational uptime rating, maintaining high-throughput precision across continuous multi-shift research and pilot operations.
Contact our battery equipment engineering team today to request a technical consultation, detailed quotation, or customized tooling configuration tailored to your specific cell chemistry and dimensions.
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