圓柱鋰電池自動包塑機(jī)行業(yè)應(yīng)用介紹

一、核心功能：全流程自動化與高精度控制

I. Core Functions: Full-Process Automation and High-Precision Control

圓柱鋰電池自動包塑機(jī)是鋰電廠實(shí)現(xiàn)高效生產(chǎn)、保障產(chǎn)品質(zhì)量的核心設(shè)備，其核心功能體現(xiàn)在以下三方面：

Automatic plastic wrapping machines for cylindrical lithium batteries are core equipment for lithium battery factories to achieve efficient production and ensure product quality. Their core functions are reflected in the following three aspects:

全流程自動化生產(chǎn)

Full-Process Automated Production

設(shè)備整合了包塑、封口、PACK組裝等工序，實(shí)現(xiàn)從電芯到成品電池包的連續(xù)生產(chǎn)。以中步擎天CTC-80S系列為例，其采用集成PLC、傳感器、步進(jìn)電機(jī)等自動化技術(shù)，支持多型號電芯（如18650、21700）快速切換，兼容性覆蓋動力電池、儲能電池等主流需求。設(shè)備節(jié)拍可達(dá)800PC/H（單工序），若整合全流程，單線日產(chǎn)能可突破1.9萬支（按8小時計(jì)算），顯著減少人工干預(yù)。

The equipment integrates processes such as plastic wrapping, sealing, and PACK assembly to achieve continuous production from cells to finished battery packs. Taking the Zhongbu Qingtian CTC-80S series as an example, it uses integrated automation technologies such as PLC, sensors, and stepper motors, supports rapid switching between multiple cell models (e.g., 18650, 21700), and its compatibility covers mainstream demands like power batteries and energy storage batteries. The equipment cycle time can reach 800 PC/H (single process). If the entire process is integrated, the daily capacity of a single line can exceed 19,000 units (calculated based on 8 hours), significantly reducing manual intervention.

高精度材料控制

High-Precision Material Control

包塑機(jī)通過伺服電機(jī)精準(zhǔn)控制包塑厚度，結(jié)合在線測厚系統(tǒng)實(shí)時反饋數(shù)據(jù)，確保每顆電池的包塑層厚度偏差≤±0.02mm。例如，某頭部電池廠引入該設(shè)備后，電池包塑層一致性提升40%，因材料浪費(fèi)導(dǎo)致的成本降低15%。

The wrapping machine precisely controls the wrapping thickness through servo motors, combined with real-time data feedback from an online thickness measurement system, ensuring the wrapping layer thickness deviation of each battery is ≤±0.02mm. For example, after a leading battery manufacturer introduced this equipment, the consistency of the battery wrapping layer improved by 40%, and costs due to material waste decreased by 15%.

智能化數(shù)據(jù)追溯

Intelligent Data Traceability

設(shè)備配備數(shù)據(jù)追溯系統(tǒng)，可記錄每顆電芯的生產(chǎn)參數(shù)（如封口壓力、包塑溫度、PACK電壓等），并與工廠MES系統(tǒng)無縫對接。某疊瓦組件企業(yè)通過該功能，將產(chǎn)品不良率從0.5%降至0.08%，客戶投訴率下降60%。

The equipment is equipped with a data traceability system that can record production parameters for each cell (such as sealing pressure, wrapping temperature, PACK voltage, etc.) and seamlessly integrate with the factory MES system. A shingled module manufacturer used this function to reduce product defect rate from 0.5% to 0.08% and customer complaint rate by 60%.

二、技術(shù)優(yōu)勢：效率、質(zhì)量與成本的全面突破

II. Technical Advantages: Comprehensive Breakthrough in Efficiency, Quality, and Cost

效率提升：柔性生產(chǎn)與快速換型

Efficiency Improvement: Flexible Production and Quick Changeover

多型號兼容：設(shè)備支持18650、21700、4680等主流圓柱電池規(guī)格，換型時間≤15分鐘（傳統(tǒng)設(shè)備需2-3小時）。

Multi-Model Compatibility: The equipment supports mainstream cylindrical battery specifications such as 18650, 21700, 4680, with changeover time ≤15 minutes (traditional equipment requires 2-3 hours).

并行加工：部分高端機(jī)型采用多工位協(xié)同設(shè)計(jì)，如中步擎天CTC-80S的"共光斑技術(shù)"，可同時完成開槽與熱裂，單工序效率提升30%。

Parallel Processing: Some high-end models adopt multi-station cooperative design, such as the "Co-Spot Technology" of Zhongbu Qingtian CTC-80S, which can simultaneously complete notching and thermal cracking, increasing single-process efficiency by 30%.

質(zhì)量保障：零缺陷控制與AI檢測

Quality Assurance: Zero-Defect Control and AI Inspection

AI視覺檢測：通過機(jī)器視覺系統(tǒng)實(shí)時檢測電芯外觀缺陷（如劃痕、凹坑）、極耳對齊度（誤差≤0.05mm）等關(guān)鍵指標(biāo)，缺陷檢出率≥99.9%。

AI Visual Inspection: Real-time detection of key indicators such as cell appearance defects (e.g., scratches, dents) and tab alignment (error ≤0.05mm) through a machine vision system, with defect detection rate ≥99.9%.

熱應(yīng)力控制：采用激光熱應(yīng)力斷裂技術(shù)（類似太陽能電池片劃片機(jī)原理），確保包塑層與電芯結(jié)合緊密，無微裂紋、氣泡等缺陷，機(jī)械強(qiáng)度提升20%。

Thermal Stress Control: Using laser thermal stress fracture technology (similar to the principle of solar cell dicing machines) to ensure tight bonding between the wrapping layer and the cell, free from defects like microcracks and bubbles, mechanical strength increased by 20%.

成本優(yōu)化：材料利用率與能耗降低

Cost Optimization: Material Utilization and Energy Consumption Reduction

材料節(jié)約：設(shè)備通過閉環(huán)控制系統(tǒng)優(yōu)化包塑材料用量，材料利用率從85%提升至95%，單支電池成本降低0.03元（按年產(chǎn)能1億支計(jì)算，年節(jié)省成本300萬元）。

Material Savings: The equipment optimizes wrapping material usage through a closed-loop control system, increasing material utilization from 85% to 95%, reducing the cost per battery by 0.03 RMB (calculated based on an annual capacity of 100 million units, saving 3 million RMB annually).

節(jié)能設(shè)計(jì)：風(fēng)冷激光器功耗降低30%，水霧冷卻系統(tǒng)節(jié)水50%，單線年電費(fèi)節(jié)省約10萬元。

Energy-Saving Design: Air-cooled laser power consumption reduced by 30%, water mist cooling system saves 50% water, saving approximately 100,000 RMB per line annually on electricity.

三、典型應(yīng)用場景：從動力電池到儲能系統(tǒng)的全覆蓋

III. Typical Application Scenarios: Full Coverage from Power Batteries to Energy Storage Systems

動力電池生產(chǎn)

Power Battery Production

4680大圓柱電池：特斯拉、億緯鋰能等企業(yè)采用自動包塑機(jī)生產(chǎn)4680電池，設(shè)備需支持無極耳結(jié)構(gòu)設(shè)計(jì)，確保包塑層與極柱的絕緣性能（耐壓≥500V）。

4680 Large Cylindrical Batteries: Companies like Tesla and EVE Energy use automatic wrapping machines to produce 4680 batteries. The equipment needs to support tabless structure design to ensure the insulation performance between the wrapping layer and the terminal (withstand voltage ≥500V).

高鎳三元電池：針對NCM811等高能量密度材料，設(shè)備需配備惰性氣體保護(hù)系統(tǒng)，防止包塑過程中材料氧化，良率提升至99.5%。

High-Nickel Ternary Batteries: For high-energy-density materials like NCM811, the equipment needs to be equipped with an inert gas protection system to prevent material oxidation during the wrapping process, increasing yield to 99.5%.

儲能電池生產(chǎn)

Energy Storage Battery Production

戶用儲能電池：大圓柱磷酸鐵鋰電池（如26650、32650）需滿足IP67防護(hù)等級，包塑機(jī)需集成氣密性檢測功能，確保電池包防水性能。

Residential Energy Storage Batteries: Large cylindrical LFP batteries (e.g., 26650, 32650) need to meet IP67 protection level. The wrapping machine needs to integrate an air-tightness detection function to ensure the waterproof performance of the battery pack.

電網(wǎng)級儲能電池：設(shè)備需支持長電芯（如高度80mm以上）包塑，通過動態(tài)調(diào)整包塑模具，適應(yīng)不同長度需求，減少模具更換成本。

Grid-Level Energy Storage Batteries: The equipment needs to support wrapping of long cells (e.g., height above 80mm), dynamically adjusting wrapping molds to adapt to different length requirements and reduce mold changeover costs.

高端市場定制化需求

Customized Demand for High-End Markets

低溫性能電池：針對-40℃低溫環(huán)境，包塑材料需采用低溫韌性配方，設(shè)備需配備低溫注塑系統(tǒng)，確保材料流動性與結(jié)合強(qiáng)度。

Low-Temperature Performance Batteries: For low-temperature environments of -40°C, wrapping materials require a low-temperature toughness formula. The equipment needs to be equipped with a low-temperature injection molding system to ensure material fluidity and bonding strength.

快充電池：為滿足4C以上快充需求，包塑層需具備高導(dǎo)熱性，設(shè)備需集成導(dǎo)熱材料涂覆模塊，提升電池散熱效率。

Fast-Charging Batteries: To meet fast-charging demands above 4C, the wrapping layer needs high thermal conductivity. The equipment needs to integrate a thermal conductive material coating module to enhance battery heat dissipation efficiency.