How does the high-precision pressure control system for supercapacitors ensure consistent tab flattening and prevent overpressure damage or insufficient pressing?
Publish Time: 2025-12-16
In the manufacturing process of supercapacitors and cylindrical batteries, the tabs (i.e., terminals) are crucial for current collection and external connection. Their flatness directly affects subsequent welding quality, internal resistance stability, and even the long-term reliability of the entire module. Insufficient flattening leads to poor contact surfaces, causing incomplete soldering or localized overheating; excessive pressure can damage the current collector, cause metal fatigue, or even microcracks, creating safety hazards. The high-precision pressure control system is the core technology for resolving this contradiction. Through real-time sensing, dynamic adjustment, and closed-loop feedback, it ensures that every flattening action falls precisely within the process window, achieving "just right" consistent processing.
The core of this system lies in its precise force sensing and millisecond-level response capability. Traditional mechanical flattening equipment relies on springs or cylinders to set fixed pressure, making it difficult to cope with fluctuations caused by batch differences in materials, changes in environmental temperature and humidity, or minor wear and tear on the equipment. Modern leveling machines equipped with high-precision pressure sensors and servo actuators can convert the actual force applied to the lugs into electrical signals in real time and compare them with preset target values. Once a deviation is detected—whether due to increased resistance caused by slight deformation of the battery casing or fluctuations in friction caused by changes in lubrication—the control system immediately adjusts the servo motor output to dynamically compensate for the pressure, ensuring that the force applied to the lugs remains within the ideal range.
This closed-loop mechanism of "sensing-judging-adjusting" not only avoids excessive metal stretching or substrate damage caused by overpressure but also eliminates warping residue caused by underpressure. More importantly, the system can adaptively match parameters for different material properties (such as aluminum or copper lugs), thicknesses, and hardnesses. For example, aluminum lugs for Supercapacitors are typically softer and require a gentler pressure profile; while composite lugs for some high-power lithium batteries require higher rigidity pressing. The high-precision control system stores multiple process formulas and enables one-click switching, ensuring optimal flattening results for all types of products.
Furthermore, the uniformity and perpendicularity of pressure application are equally crucial. The high-quality flattening machine employs a precision guiding mechanism and parallel pressure head design to ensure that pressure is applied perpendicularly to the tab plane, preventing lateral forces from causing twisting or displacement. Combined with a flexible buffer structure, it can absorb minor assembly errors and prevent localized stress concentration. The entire flattening process is smooth and impact-free, protecting the integrity of the battery casing and ensuring the continuity of the tab's microstructure.
At the quality control level, the system typically integrates process data recording functions, allowing traceability of parameters such as the flattening pressure curve, peak value, and duration for each battery. Any abnormal trends can trigger early warnings of equipment maintenance needs or material issues, shifting from "post-inspection" to "process error prevention." This not only improves yield but also provides a fundamental guarantee for the safety of the battery throughout its entire lifecycle.
In summary, the high-precision pressure control system of the Supercapacitor flattening machine is far more than a simple "pressurization device"; it is an intelligent process execution unit integrating sensing, control, and materials understanding. With millimeter-level precision and gram-level accuracy, it safeguards the first line of defense for the efficient and safe transfer of electrochemical energy within a small space. Behind this seemingly silent flattening action lies an unyielding pursuit of ultimate consistency—because every millivolt of stability begins with a perfectly timed pressing.
