Semi Automatic Z Fold Stacking Machine for Prismatic Lithium Ion Power Batteries

Product Overview

This system is a semi-automatic Z-fold stacking solution engineered for the stacking process of prismatic lithium-ion power cells. It combines motor-driven separator unwinding, tension control, web correction, electrode pickup, secondary positioning, stacking-table compression, separator cutting, and cell transfer in one coordinated workflow. The result is controlled layer placement for manufacturers that need repeatable electrode and separator registration rather than a purely manual stacking operation.

The equipment is suited to lithium-ion power battery production where positive and negative electrodes must be alternately stacked with separator material in a Z-fold pattern. It supports pilot-line work, process development, and production operations for prismatic cells, including programs serving electric mobility, stationary energy storage, and industrial battery applications. Manual tape application and manual cell removal remain integrated parts of the defined operating sequence.

Built around active separator handling, multi-stage electrode positioning, and four cross-operating pressing blades, this unit is designed to maintain orderly stack formation under demanding cell-manufacturing conditions. Measures for sheet separation, dust extraction, and blade withdrawal help protect electrodes, support stable operation, and reduce process-related defects attributable to the machine.

Key Features

• Z-Fold Separator Handling: The separator is motor-unwound and routed through tension-control and correction mechanisms before reaching the stacking table. This controlled web path supports separator alignment while the stack position changes from side to side.

• Alternating Electrode Placement: Left and right reciprocating manipulators use suction cups to retrieve positive and negative electrodes from material boxes. Each electrode passes through a secondary positioning platform before placement, providing a defined positioning step before stacking.

• Precision Registration Control: The equipment is specified for center deviation between electrodes and separator of +/-0.4 mm, separator end-face alignment of +/-0.3 mm, adjacent-electrode alignment of +/-0.2 mm, and overall electrode alignment of +/-0.3 mm. These values give process teams clear reference points for stack geometry control.

• Four-Set Cross-Acting Compression: Four pressing-blade mechanisms operate in a cross pattern on the stacking table to compact the electrode layers. Controlled pressing helps keep the layer sequence in place as the Z-fold stack is formed.

• Electrode-Protective Blade Buffering: Before a pressing blade retracts, it lifts slightly away from the electrode. This buffered withdrawal is designed to prevent the blade from pulling or damaging the electrode surface during the stacking cycle.

• Multi-Measure Sheet Separation: Material-box air blowing, sheet-separating brushes, and external-suction-cup manipulator shaking are used to control multiple-sheet pickup and missed-sheet events. These mechanisms address common feed-stage risks before the electrode reaches the positioning platform.

• Integrated Dust Extraction Points: Effective dust-extraction provisions are installed at both the material boxes and the secondary positioning area. This supports cleaner electrode handling at two locations where loose particles can affect material management and positioning work.

• Defined Cell Completion Sequence: Once stacking is complete, the separator is cut and a cell transfer mechanism removes the cell from the stacking table. The operator applies tape and removes the cell while the equipment begins automatic stacking of the next cell, supporting a practical semi-automatic workflow.

• Configurable Layer Count: The number of stacked layers can be set within the applicable thickness range. This allows process setup to follow the thickness limits of the intended cell stack rather than forcing a fixed layer count.

• Production-Focused Availability Targets: The specified qualification rate is 99% for defects caused only by the machine, while the specified operating rate is 98% for failures caused only by the machine. These defined boundaries help procurement and manufacturing teams assess equipment performance in the proper operating context.

Applications

Technical Specifications

Why Choose This Product

• Alignment-Centered Engineering: The system specifies distinct tolerances for electrode-to-separator registration, separator end faces, adjacent electrodes, and overall electrode alignment. This provides a more complete basis for managing the geometry of a stacked cell.

• Protection Built Into the Motion Sequence: Buffered pressing-blade withdrawal, secondary electrode positioning, controlled separator handling, and several sheet-separation measures address risks at the feed, placement, compression, and separator stages. These details are important where electrode condition and layer order must be protected throughout repeated cycles.

• Robust Semi-Automatic Workflow: Automatic stacking proceeds alongside defined operator tasks for tail winding, tape application, and finished-cell removal. The sequence allows teams to establish disciplined material handling while retaining manual control at the final completion steps.

• Operationally Relevant Performance Targets: A specified stacking speed of 1.3-1.6 s/pcs, 99% qualification rate for machine-caused defects, and 98% operating rate for machine-caused failures provide procurement teams with practical performance indicators for line planning and equipment evaluation.

• Installation Requirements Clearly Defined: Electrical, pneumatic, environmental, loading, and vibration requirements are stated for facility planning. Clear operating boundaries help teams prepare an appropriate installation location and protect long-term equipment consistency.

Contact us for a quote or a custom solution matched to your prismatic lithium-ion power battery stacking process.

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