A robotic arm or linear module transports battery halves and fixtures onto the welding strip. The strips are then moved by a welding belt to the infrared lamp heating zone for welding the grid lines of the battery halves to the welding strip. After multi-hall welding, the strips are cut to form battery strings. ZP Motor's complete stringer solution helps customers achieve equipment capacity of 10,000+ units, significantly improving module production efficiency
Case Details
Module StringerA robotic arm or linear module transports battery halves and fixtures onto the welding strip. The strips are then moved by a welding belt to the infrared lamp heating zone for welding the grid lines of the battery halves to the welding strip. After multi-hall welding, the strips are cut to form battery strings. ZP Motor's complete stringer solution helps customers achieve equipment capacity of 10,000+ units, significantly improving module production efficiency while reducing breakage rates.
Challenges Facing the IndustryHigh Technical Complexity & Expensive Imported Control Stations
Multi-busbar technology increases the number of welding strip feeding axes in the stringer, with the total number of servo + stepper axes approaching one hundred. This places higher demands on the performance and stability of the control station, and currently, foreign brand control stations are very expensive.
Difficult Equipment Debugging
The technical complexity and precision requirements of multi-busbar stringers necessitate frequent modifications to system and servo parameters to achieve better welding results, significantly impacting batch installation efficiency.
Higher Installation Space Requirements: The increased number of feeding shafts in multi-busbar serial welding equipment leads to a greater number of motor controllers, resulting in a more compact electrical control cabinet and stricter requirements on the size of the products within the cabinet.
Capacity and Efficiency Issues: Although multi-busbar technology can improve component conversion efficiency and reduce production costs, in actual production, the efficiency of typical domestic alternatives is relatively low, directly impacting the overall production capacity of the enterprise.
Solution Features:High Cost-Effectiveness of Main Controller: Up to 25% Cost Savings: Zhongping Motor's LC5000 series intelligent production line controller is based on an X86 architecture + CODESYS motion control platform architecture, with zero hardware replacement costs. The integrated solution of main station + module + servo + stepper offers high cost-effectiveness, saving 10%~25% on the overall cost.
Thinner Drive Size: 50% Installation Space Savings: Zhongping IO dual-axis stepper system is thinner and more economical. It saves 50% on installation space and communication cables, reducing control and development costs.
High-Efficiency Cell Placement Algorithm: Zhongping's cell placement algorithm can accommodate commonly available module specifications. During line changes, only the number of cells per string and the cell spacing need to be input for seamless switching of cell production types. Zhongping's high-speed interpolation function enables rapid and precise movement of both internal and external wire-drawing modules.
Value Realized:Compatible with multi-process cells, supports round and irregularly shaped solder strips and finer welding wires, and can be upgraded to various 0BB processes.
Flexible belt conveyor suitable for thinner cells.
Reduced cell turnover, lower breakage risk.
Short cutting time, low maintenance costs, and can be upgraded to more welding processes.
