CORPORATE CONTENT: ERHARDT & LEIMER
The battery industry is operating in an area of tension between increasing production volumes and, at the same time, the highest demands for quality, safety, and efficiency. Particularly in lithium-ion batteries, even the smallest deviations in material thickness directly affect the performance, energy density, and service life of the cells. Especially in electrode production, in addition to basis weight measurement in the coating lines, thickness measurement after the press rollers is of crucial importance for the functionality of the cells. Only the continuous measurement of material thickness after the press makes it possible to detect deviations and correct them accordingly. This ensures the required capacity as well as uniform material homogeneity and reduced porosity in subsequent processes.
The demand for ever higher line speeds while maintaining consistent quality places enormous requirements on measuring technology. Conventional measuring methods quickly reach their limits here, whether due to insufficient accuracy, inadequate stability, or complex integration into existing systems. What is required are solutions that can measure precisely, non-contact, and continuously without negatively influencing the production process.
Precise measurement as the basis for stable processes
In battery production, thickness measurement is not an isolated step, but an integral part of process control. While the focus in coating lines is on basis weight, thickness measurement is of decisive importance particularly in the pressing process. Here, the coated material is compacted so that the final thickness and therefore the corresponding energy density of the cell are achieved. Automatic thickness measuring systems ensure accuracies in the micrometer range and make a significant contribution to process stability.
Continuous online measurement offers decisive advantages. Deviations are detected immediately, control loops can react in real time, and production waste is significantly reduced. Thus, transparency in the production process increases, which is of central importance in the context of Industry 4.0 concepts and data-driven optimization, and serves as the basis for AI.
Non-contact online thickness measurement EL-THICKNESS for the highest demands
With EL-THICKNESS, Erhardt+Leimer offers a solution designed for the special requirements of battery production. The system enables continuous, non-contact measurement of material thickness and supports manufacturers in maintaining constant quality standards and controlling production processes efficiently.
At the core of the system is the use of state-of-the-art sensor technology. Chromatic-confocal sensors guarantee high-precision detection of material thickness and allow accuracy up to a micrometer. Even the smallest fluctuations can therefore be reliably detected and compensated. This is crucial particularly for sensitive electrode materials, where every deviation can have a direct impact on cell performance. An integrated MSA test to ensure measuring equipment capability is a fixed component of the system.
Stability and dynamics thanks to the C-frame made of CFRP
A key differentiating feature of the EL-THICKNESS system is the innovative C-frame made of carbon fiber reinforced polymer. Compared with conventional granite frames, this design combines several decisive advantages that directly affect measurement quality and integration into production lines.
Thanks to its high stiffness combined with low weight, the carbon fiber frame offers exceptional stability, which can be further optimized through design modifications with a negligible increase in weight. This results in additional advantages compared to other materials. At the same time, the CFRP frame exhibits very low thermal expansion, meaning that measurement deviations can be disregarded even with minor temperature fluctuations. This ensures consistently reproducible measurement results – even under the most demanding production conditions.
The low weight of the CFRP frame significantly reduces installation effort, making integration into new or existing systems much easier. In addition, the slim design allows space-saving installation in often confined production environments.
Technological performance
The EL-THICKNESS system with C-frame made of CFRP impresses not only with its mechanical properties, but also with its metrological performance. Chromatic-confocal sensors enable measurement accuracy better than 1 µm.
The integration of currently common interfaces such as EtherNet/IP or Profinet, as well as support for established interfaces such as Profibus, ensures seamless integration into existing control and automation systems. This allows the system to fit perfectly into modern, networked production environments and supports the implementation of data-based optimization strategies.
Added value for battery production
For manufacturers in the battery industry, the use of the EL-THICKNESS system creates clear added value. High-precision, continuous thickness measurement enables a significant reduction in production waste and rework. At the same time, process stability is increased, which directly results in consistently high product quality.
The system also supports more efficient use of resources. Through exact compliance with material specifications, material consumption can be optimized by reducing the scrap rate. This is not only economically relevant but also contributes to a more sustainable production process.
Last but not least, continuous data acquisition creates the basis for further analyses and optimizations. In combination with higher-level systems, trends can be identified at an early stage, maintenance measures can be planned more effectively, and production processes can be improved in a targeted manner.
Conclusion
The requirements for battery production will continue to rise, both in terms of quality and efficiency. High-precision and reliable measuring systems are therefore a key factor for success. With the EL-THICKNESS system and the innovative C-frame made of CFRP in combination with the latest sensor technology, Erhardt+Leimer offers a future-proof solution that combines the highest measurement accuracy with robust design and easy integration.
