English (UK) 
简体中文 Conveyance Challenges in New Energy Battery Production
The manufacture of new energy batteries places severe demands on the conveyor system.Cell Thermal Sensitivity(Temperature fluctuation needs to be <±2℃).Heavy duty 100kg(Packs up to 2000kg).Anti-static grade(dissipation time <0.1 sec) andCleanliness standards(ISO 14644 Class 5). There are three major bottlenecks facing conventional single-deck conveyor lines:
- Space inefficiencies: The floor plan takes up more than 70% of plant area, restricting capacity creep;
- risk of losing control of the beat: Manual handling results in a PACK misplacement rate of up to 3%, affecting assembly accuracy;
- Weak environmental adaptation: Leakage of electrolyte is prone to corrosion of rails, and dust intrusion triggers short circuits.
personal viewpoint: The nature of manufacturing new energy batteries is"The Art of Balancing Precision and Safety.". Actual measured data from a head battery factory shows thatThree-dimensional circular conveying system increases capacity per unit area by 2.3 times, while reducing the risk of electrolyte exposure for 25% - corroborating the"Spatial reconfiguration" is a better solution than line expansion to the conflict between high safety standards and low-cost manufacturing..
Three-dimensional cyclic architecture with double speed chain
Mechanical Innovation: The Symbiosis of Heavy Duty and Cleanliness
- Two-speed domain drive: Upper fully loaded chain speed 18 m/min, lower no-load return 8 m/min, viaElliptical Wheel Lifting System(Patent CN202222905222.0) Achieve stepless adjustment of layer height from 0.8 to 2.5 metres, suitable for full-size delivery from electric core to PACK pack;
- Triple anti-interference design::
- seismic defences: Hydraulic damper absorbs Class VII vibration, 2000kg load deflection ≤ 0.5mm;
- corrosion protection: Nickel-plated stainless steel chains are resistant to acid and alkali electrolyte attack (3.2 times longer life);
- electrostatic protection and control: Copper alloy guide rail + conductive roller combination, charge dissipation <0.1 sec.
Intelligent control: data-driven precision beats
- Dynamic scheduling enginePLC synchronisation of the loader and chain via EtherCAT bus, blocker response <50ms;
- Fault pre-adaptation: Lower level preset cache track, automatic shunt when sensor detects abnormality, fault impact range reduced to 30%;
- energy efficiency synergy: Automatic speed up 25% during the valley power hours, Schneider ATV630 frequency converter recovers 23% braking power, and the comprehensive energy consumption is reduced by 35%.
Digital Twin Pre-Control System
- Virtual Load Testing: Simulation of the 300kg load limit to predict the deformation point, the commissioning cycle is reduced from 14 days to 5 days;
- heat map positioning: Identify high-risk areas for wear in high-altitude turning sections and increase chain life by 2.8 times with additional lubrication points.
Disruptive application scenario breakthroughs
Closed loop battery PACK process
- Core sorting section: Upper level of the double-layer chain transports bare cores to the soldering station and the lower level returns unloaded antistatic trays (cleanliness maintained at Class 5);
- Module assembly sectionHydraulic support platform (Patent CN219905685U) sharing the weight of 60% module, synchronous accuracy ±0.05mm;
- PACK Lower Line SegmentThe Z-type hoist connects to the test chamber, completing a 3-metre lift in 90 seconds, saving 30% and eliminating the risk of tipping.
Battery Circulation System for Exchange Stations
- Bilateral switching mode: Multiplier chain directly connects the charging compartment with the power change station, synchronous delivery of full/loss battery packs, cancellation of the power change trolley track, and maintenance cost reduction of 42%;
- Pre-workstation mechanismThe first prep station caches fully charged batteries, the second prep station temporarily stores batteries with a loss of power, and the changeover beat is compressed to 3 minutes/unit.
controversial insight: Industry practice"Material upgrades" to address environmental adaptationbut the case of a photovoltaic company reveals -Environmental Data Prediction SystemBy analysing the correlation between chain wear and temperature and humidity, the seals are automatically strengthened before the rainy season, and downtime is reduced to 4 hours/year, lowering O&M costs by 47% compared to simply switching to ceramic coatings.Intelligent pre-adaptation is becoming a hidden lever to reduce costs and increase efficiency.
The Triple Paradigm of Technological Evolution
Flexible production support
- Quick release link systemCarbon steel chain link + self-locking pin design, changeover time <30 minutes (traditional 4 hours), support line reorganisation within 2 hours;
- Interface pre-built redundancy: Guide rail T-slot compatible with RFID readheads and vision sensors, positioning accuracy ±0.1mm.
Extreme Scene Conquest
- High-temperature welding areaNitriding treatment chain is resistant to 600℃ spark splash, continuous failure rate <0.5%;
- Cryogenic injection booth: Reserve 0.2mm/m expansion joint for guide rail to eliminate -20℃ cold shrinkage stress.
cross-device collaborative network
- multiprotocol communicationProfinet/EtherCAT dual interface supports AGV/mechanical arm co-response <50ms;
- IIoT Integration: MES system remotely regulates conveyor beats, order switching efficiency increased by 55%.
Self-questioning: the core concern of smart upgrading
Q: How to protect the conveyor line from electrolyte environment?
A: A dual track of material upgrades and smart monitoring is required:
- physical isolation: Fully sealed rails + silicone strips to block liquid and gas permeation;
- electrochemical protection: Nickel-plated stainless steel chains are resistant to hydrofluoric acid corrosion;
- early warning of a leak: Integrated pH sensor in the rail for real-time monitoring of electrolyte concentration.
Q: How can small and medium-sized battery factories be transformed in phases?
A: Economic "three-step" strategy:
- initial stage: Carbon steel base model (costs 35% less than stainless steel) with fixed lower height;
- mid-term: Add inverter module to realise valley power speed control, 1.5 years payback;
- at a fixed date in the future (e.g. for repayment): Deploying a digital twin reduces O&M costs by another 42%.
Q：How to prevent vibration for 2000kg battery packs conveyed at high speed?
A: Mechanical and intelligent synergistic damping:
- structural design: Double-row speed chain + hydraulic load-bearing platform to spread the load;
- dynamic compensation: Accelerometers monitor vibration in real time, slowing down to 8 m/min when thresholds are exceeded;
- Path optimisation: Avoid sharp turns, minimum radius of curvature ≥ 1200mm.
The dance of rollers and algorithms is reconfiguring the dimensions of manufacturing efficiency as a double-decker multiplier chain carrying 300kWh of solid-state batteries hurtles at 18m/min at 15 metres altitude. A real-world test by a car company reveals."Spatial capacity density" of the three-dimensional circulation system(capacity/energy consumption per unit volume) is 3.1 times higher than that of traditional single-layer lines - a sign that the competition in new energy manufacturing has shifted from "single-point efficiency" to "single-point efficiency"."Data Penetration Wars in Stereospace."In the next ten years, the core indicator of the advanced battery production line may no longer be the number of cells delivered per minute but the entropy reduction intensity per cubic metre of plant space. In the next ten years, the core indicator for judging the advancement of battery production lines may no longer be the number of cells delivered per minute, but the entropy reduction intensity of safety and efficiency per cubic metre of plant space.
