How do sleeving machines for supercapacitors achieve automated "tube threading in seconds"?
Publish Time: 2025-08-25
On automated production lines for cylindrical lithium-ion batteries, every step strives for high speed, high precision, and high consistency. "Tubing"—the process of precisely inserting insulating tubing (such as PVC, PET, or heat-shrink tubing) into the battery casing—may seem simple, but it actually has a significant impact on efficiency and product yield. Traditional manual tube threading is not only slow and error-prone, but also carries risks such as scratching the battery and reverse insertion of the tubing. Modern sleeving machines for supercapacitors, through highly integrated automation systems, can complete one or even multiple tube threading operations per second, truly ushering in the era of "tube threading in seconds."
1. Multi-station Synchronous Operation: Parallel Processing Improves Cycle Time
The key to "tube threading in seconds" lies in overcoming the time bottleneck of "single-operation" operations. High-end tube threading machines utilize multi-station rotary or linear structures, breaking down the entire tube threading process into multiple, sequential stations: loading, positioning, tube threading, inspection, and unloading. During operation, each station works in parallel: while one group of batteries is being threaded, the next group is already being positioned, and the next group has completed inspection and is ready for discharge. This "assembly line"-style coordinated operation reduces the threading cycle to 0.3–0.8 seconds, and the overall efficiency reaches over 400–2,000 units per minute, far exceeding the limits of manual operation.
2. High-speed, precise feeding system: Ensures "zero-delay" supply of batteries and casings
Automated casing threading requires stable, high-speed material supply. The equipment is equipped with a vibrating plate and a linear feed track or a robotic gripper system to automatically arrange and directional transport the batteries. Simultaneously, insulating casing is continuously fed by an automatic coil unwinding device, and the cutting length is precisely controlled by a servo motor. Once the casing is cut, it is immediately fed into the clamping mechanism of the threading station. The entire process requires no manual intervention, ensuring that each battery receives the matching casing within the predetermined timeframe, eliminating waiting and idling.
The key to successful threading lies in centering accuracy. The equipment utilizes high-precision guides and a servo-driven threading head, coupled with photoelectric sensors or machine vision systems, to monitor battery position and casing posture in real time. Once the battery enters the threading station, pneumatic or electric clamps quickly secure the battery ends to prevent misalignment. Subsequently, the threading needle pushes the casing through the battery from one end with high speed and stability, precisely covering the designated area. Some models also utilize "dual-needle simultaneous threading" technology, pushing the casing simultaneously from both ends to prevent wrinkling or skewing, ensuring a neat, wrinkle-free, and bottom-free appearance after threading.
4. Intelligent Inspection and Rejection: Achieving 100% Process Quality Control
"Speed" must be based on "accuracy." After each threading cycle, the equipment automatically determines whether there are any defects, such as missing threads, reverse threads, casing damage, or misalignment, using a visual inspection system or photoelectric sensors. Once a defective product is detected, it is immediately marked and automatically separated by a rejection mechanism, ensuring that every battery entering the next process meets standards. This real-time closed-loop control not only ensures product quality but also avoids waste and downtime in subsequent processes.
5. Modular Design and Rapid Changeover: Adapting to Multi-Specification Battery Production
To meet the production needs of diverse battery models, modern tube threading machines generally adopt a modular design. Changing battery specifications requires only calling a preset program, replacing the corresponding mold, or adjusting the fixture size. This changeover can be completed in minutes, eliminating the need for hours of downtime. Some high-end equipment also supports automatic size recognition and parameter matching, further enhancing flexible production capabilities.
The "second-level tube threading" achieved by the sleeving machine for supercapacitors is not the result of a single technological breakthrough, but rather the result of a deep integration of mechanical structure, motion control, sensor detection, and intelligent algorithms. It transforms a tedious operation that once relied on manual experience into a high-speed, precise, and replicable automated process, significantly improving production efficiency while providing a solid guarantee for battery safety and consistency. Today, with the rapid development of the new energy industry, such "invisible weapons" are silently supporting the efficient birth of every cylindrical battery.
