building better batteries - honeywell...tracking separator (biax) process using quality optimizer 7...

EMEA HUG – Pulp and Paper / Continuous Web SolutionsBUILDING BETTER BATTERIESPeter DeNicola

September 25, 2019

Honeywell Confidential - © 2019 by Honeywell International Inc. All rights reserved.

LiB energy storage touches many facets of our lives

1

Home / Portable Devices

• Mobile phones and tablets

• Laptop computers

• Power and garden tools

• Flashlights, landscape lighting…

Electric Industry / Grid / Off-Grid

• Wind and solar storage

• Home storage, UPS

• Battery Energy Storage Systems (BESS)

Electric Vehicles

• Hybrid and electric vehicles

• Trucks

• Light commercial vehicles, shuttle busses

• Commercial and public transportation

Industrial Applications

• Forklifts and loaders

• Construction equipment and vehicles

• Mining and marine

• Agriculture

Lithium Ion Batteries – enormous growth to meet global needs


By 2027, total EV battery demand will be 400GWh

2

LiB Growth Requires High-Quality Manufacturing Processes

• Global demand driving new LiB plant construction

• Europe has minimal existing LiB production capacity


Lithium Ion Batteries are critical to Renewable-Energy Solutions

3

“Look Inside” – Honeywell QCS integral to LiB ManufacturingQCS in LiB

supply chain• Aluminum rolling

mill – cathode

base

• Electro-deposited

copper film –

anode base

• Biaxial line –

separator film

QCS in LiB

manufacturing

• Anode coating

• Cathode coating

• Pressing

Note:

QCS controls

aluminum sheet

and films used in

solar panels


Parallel steps for anode and cathode components

4

Key Steps in Battery Manufacturing

Final

Assembly

Test

Coating -

Carbon

Coating – Li

Metal Oxide

Mix

Copper foil

Electroplate

or rolling mill

Anode

coating

dual-side

Cathode

coating

dual-side

Aluminum

foil

rolling mill

Coat

drying

drying

Dry

pressing

pressing

Press

slitting

slitting

Slit

Separator

film biaxial

line

Case

Material

Separator

Ceramic

Coating

Winding and

assembly

Separator

film slitting

Critical to Quality

• Coating position

• Coating uniformity

• Coating thickness

• Separator film characteristics


jumbo rolls

broken down to

cell units here

Aluminum and

copper coils,

separator film

typically

manufactured

offsite and

shipped to

battery

manufacturing

plant

ANODE(-)CATHODE(+)

electrode

coating

pressing

fault detect

slitting

mixing

in b

atc

h/r

oll

un

its

SEPARATOR

ceramic coating

prep

slitting

aluminum foil copper foil

raw

ma

teria

l

Li metal oxide carbon

electrode

coating

pressing

fault detect

slitting

mixing

polymer resin

mineral oil1 2

3

fault detect

biaxial

sheet process

4

7

5

6

7

Aluminum foil (cathode current collector)

Fixed point MXProLine MetalsMaster with

AGC/AFC

1

Copper foil (anode current collector)

Scanning measurement (deposition) or

MetalsMaster (rolling)

2

Electrode coating

Subtraction-method coat weight using multiple

scanners

3

Biaxial sheet process

Cast/Film measurement MXProLine with Advanced

Profile Control

4

Data historian, process & quality analytics

Tracking separator (Biax) process using Quality

Optimizer

7

Ceramic coating

Measure base sheet and ceramic coating using

IR/X-ray sensors

5

Pressing

Measure thickness of top/bottom coating after

calendaring

6

MXProLine controls inbound metal coils, coating, pressing, and separator film

Continuous Process Through SlittingHoneywell QCS Solution

5


Requirement Honeywell

Scan to both edges and off the edge to precisely determine edge position

for each scanner to compensate MD & CD stretch ✓

1ms sensor response time to precisely measure step change from coated

area and non-coated area ✓

Real-time direct scanner to scanner communication to keep

synchronization during total scan path including acceleration/deceleration

phases to avoid clipping and tracking problems✓

High precision head tachometer synchronization with scanner controller to

prevent position error ✓

High calibration accuracy over a wide range of measurement (no coat, +

one side ~ 100 GSM, + two sided ~ 200 GSM) ✓

Accurately measure both top and bottom coating

✓

Flexible software configuration and tuning tools to keep high performance,

can be done by customer ✓

Honeywell MXProLine QCS operating in LiB Lines since 2001

Anode and Cathode coating are critical manufacturing steps

• > 150 LiB QCS delivered

• Unique measurement and control capabilities

– Sensors

– Control applications

– Quality

– Traceability

Coated

aluminum

Cathode

Coated

copper

Anode

6


Separator film structure critical to electron flow and battery performance

Discrete Assembly into Battery Cells

Battery Structure and Layers: Cathode, Separator, Anode

Separator

7

© 2019 by Honeywell International Inc. All rights reserved.

8

Typical LiB Coating Line (Anode or Cathode)


9

Anode and Cathode Coating Process

Coater

Coater

Dryers

Measure

MeasureMeasure

Measure Measure

Critical to Quality: Coating Thickness, Position, Uniformity


Thickness Measurement Must Differentiate Coated/Uncoated Areas Precisely

10

Coating Patterns Vary by Battery Application


MXProLine User

Engineering Station

Honeywell solution for Anode and Cathode Coating Lines

QCS Solution for Coating: MXProLine – World’s first IIoT QCS

MD /CDDamper Control

BW, Moi, Crepe, Coord. Speed

Measurement LAN

OPC-DA

Inbound

traffic ONLY

4G Router

Outbound

traffic ONLY

AMQP – Advanced

Message Queuing Protocol

Honeywell

Cloud

Secured Data

Edge Device

- Supports up to 3

Proline servers

https://qcs.demo.dev.connectedplant.honeywell.com

Operator

clients

11

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https://qcs.demo.dev.connectedplant.honeywell.com/


Anode and Cathode use different pressing stations for precise material control

12

Pressing Station

Energy density of

electrodes is

determined by the

pressing/compaction

step which impacts

the ohmic contact

resistance and

electrochemical

impedance

Single-point

measurement

provides required

information


13

Typical Separator Film Line

Critical to Quality: Thickness and Porosity

Battery separator film is a non-conducting, porous sheet

inserted between positive and negative electrodes to provide

a chemical barrier but allow passage of electrolytes and ions.


14

Ceramic Coating Process

Critical to Quality: Coating Thickness, Position, Uniformity

MXProLine Ceramic

Thickness

Measurement

Sensor is in

development for

2020 release


Honeywell QCS ensures high quality LiB components critical to renewable energy growth

15

Conclusion

• Demand for Lithium Ion Batteries will continue rapid growth for several years

• Major LiB Manufacturing facilities are under construction or planned, with continued CAPEX investment and expansion strategies

• Honeywell Quality Control Systems (QCS) have been solving difficult measurement and control challenges in several LiB manufacturing processes since 2001

– Aluminum and Copper base films for cathode and anode components

– Battery anode and cathode coatings measurement and control

– Pressing station thickness control

– Separator film production

– Ceramic coating (2020 introduction)

• Honeywell’s QCS 4. cloud-based solution for QCS system health and control performance compliments the on-premise control systems and provides automated monitoring and alerting for the entire enterprise

building better batteries - honeywell...tracking separator (biax) process using quality optimizer 7...

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