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Produkcja akumulatorów – energia przyszłości

Sektor energetyczny przechodzi radykalną transformację. Podczas gdy przemysł motoryzacyjny zmierza w kierunku transportu neutralnego pod względem emisji CO2, na znaczeniu zyskują również systemy magazynowania energii z odnawialnych źródeł i przenośne urządzenia elektroniczne.

Nasze produkty z serii WAGO I/O System Field to rozwiązanie, pozwalające w pełni zautomatyzować proces produkcji ogniw akumulatorowych. Z kolei zasilacze z serii Pro 2 są wyposażone w zaawansowany interfejs komunikacyjny, który umożliwia indywidualne monitorowanie i ocenę produkcji akumulatorów oraz jego optymalizację, a tym samym redukcję kosztów.

Etapy produkcji akumulatorów

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Mieszanie

Proces produkcji akumulatora rozpoczyna się od tak zwanego „przygotowania zawiesiny“. Polega to na połączeniu dwóch oddzielnych materiałów wyjściowych (anodowego i katodowego) w celu utworzenia zawiesiny. Do przygotowania wymagane są dodatki przewodzące, rozpuszczalniki i spoiwa. Decydującą rolę odgrywa tu temperatura. Sterowniki WAGO I/O System Field i WAGO PFC200 sterują temperaturą cieczy, która musi mieścić się w zakresie od 20 do 40 stopni Celsjusza. Nasze liczniki MID są wykorzystywane do monitorowania zużycia energii. Ponieważ cały proces odbywa się w pomieszczeniach sterylnych, transport zawiesiny do kolejnego etapu produkcji, jakim jest „powlekanie“, odbywa się rurociągami lub w hermetycznie zamkniętych zbiornikach.

Powlekanie i suszenie

W procesie powlekania folia nośna jest pokrywana lepką cieczą za pomocą narzędzia aplikacyjnego w celu wytworzenia powłoki. Folia nośna składa się z materiałów takich jak folia aluminiowa lub miedziana. Grubość warstwy, zgodnie z konstrukcją ogniwa, wynosi od 10 do 25 μm.

W zależności od systemu górna i dolna część folii są powlekane sekwencyjnie lub jednocześnie. Aby zachować wysokie standardy jakościowe w produkcji akumulatorów, WAGO I/O System Field i WAGO I/O System 750 monitorują precyzyjnie grubość nakładanej warstwy.

Po zakończeniu procesu powlekania następuje suszenie. Folię aluminiową lub miedzianą umieszcza się w suszarce. Przy równoczesnej obustronnej powłoce stosuje się tzw. suszarkę pływającą. Długość suszarki ma decydujące znaczenie dla osiąganej przepustowości. Suszarka jest podzielona na różne strefy temperaturowe w celu realizacji indywidualnego profilu temperaturowego. WAGO I/O System Field wraz z WAGO PFC200 to idealne rozwiązanie do precyzyjnego pomiaru i monitorowania temperatury.

Kalandrowanie

Podczas kalandrowania, zwanego również walcowaniem, powlekana po obu stronach folia miedziana lub aluminiowa jest kompresowana przez obracające się walce. Nacisk liniowy określa porowatość powleczonego podłoża. Ustawienie zbyt wysokiej wartości nacisku liniowego może spowodować zmiażdżenie lub uszkodzenie materiału podłoża. Proces walcowania służy do wyrównania najmniejszych nierówności. Dzięki wytrzymałej konstrukcji WAGO I/O System Field i WAGO I/O System 750 idealnie sprawdzają się podczas monitorowania procesu walcowania.

Cięcie

Cięcie to proces rozdzielania, w którym szeroki rdzeń elektrody (cewka macierzysta) jest dzielony na kilka mniejszych odcinków (cewki potomne). Cięcie może być wykonywane termicznie (cięcie laserowe) lub mechanicznie (cięcie nożem walcowym). Czystość rdzeni elektrod ma kluczowe znaczenie, ponieważ zanieczyszczenia lub pozostałości mogą pogorszyć jakość cewek potomnych, a ostatecznie wydajność ogniwa akumulatora. Rdzenie elektrod są czyszczone przez odsysanie i/lub szczotką, aby zapewnić płynne działanie i jakość podczas produkcji. Szerokość cięcia cewek potomnych może się różnić w zależności od konstrukcji ogniwa i w wielu zastosowaniach wynosi od 100 do 300 mm.

Montaż ogniw

Etap procesu cięcia jest wymagany do wyprodukowania ogniwa woreczkowego i dotyczy oddzielenia blach anodowych, katodowych i separacyjnych od materiału rolki – cewki potomnej. Proces cięcia jest wykonywany za pomocą nożyc (narzędzie wykrawające) lub termicznie (cięcie laserowe). Niepowleczony obszar krawędzi blachy ogniwa akumulatorowego wykorzystywany jest w późniejszym etapie procesu do spawania końcówki stykowej.

Napełnianie elektrolitem i formowanie

Napełnianie elektrolitem jest ostatnim etapem produkcji akumulatora i następuje po umieszczeniu zestawu ogniw w opakowaniu. Otwory są zamykane w procesie uszczelniania lub za pomocą wkładki trzpieniowej z przyspawaną nasadką uszczelniającą. W ogniwach okrągłych i pryzmatycznych przeprowadza się następnie wstępne starzenie, aby zapobiec deformacji spowodowanej tworzeniem się gazu.

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