NDC Introduces New Software and Controls Capability for the Lithium Ion Battery Making Process

There is hardly a device that we use in our daily business and home life that doesn't rely on a Lithium Ion power source, be it a laptop, mobile cellular phone or, increasingly, our vehicle, as the world steps up development and production of high-efficiency Lithium Ion batteries for hybrid and soon-to-be launched plug-in electric cars.

Active in this market since the mid 1980s, NDC, the USA and Europe based manufacturer of measurement and control systems for process industries, announces enhancements to its Spot-On™ software platform for its well established TDi System, with controls capability to help battery makers operate their processes more efficiently and within specification limits, while improving product consistency and process insight.

The Spot-On™ Coating Application Software includes the following features of critical interest to Li-Ion Battery manufacturers:

Same Spot Measurement, to eliminate any influence from substrate thickness variability in the coating thickness calculations

True Net Coat software, to provide true coating thickness measurement, independent of density and composition variation between substrate and coating

Variable Isolation software, to segregate Cross Direction from Machine Direction variations to improve control performance and speed of response

Gap Exclusion software for patch coating to identify and accurately measure coated versus uncoated areas of the substrate

NDC's TDi System (Total Distributed Intelligence) accurately measures the thickness or mass of the L-Ion coating, whether the L-Ion is applied as a continuous or patch coating to the aluminum or copper foil substrate.

Non-contacting real-time measurements are achieved using either Beta (transmission) or Gamma (single-sided backscatter) sensors, depending on the product weight range, to first measure the mass of the substrate and then the total mass after the coating machine. The software accurately computes the coating mass independently of the substrate and excludes the uncoated gaps, to provide a reliable control signal to the actuator for process automation.

The Sensors are mounted on NDC's MiniTrak Scanning Frames whose positional precision permits same spot differential measurements. Many competitor systems use same line measurements but this provides much lower resolution. NDC's positional accuracy is better than +/- 1mm even on dual sided coatings. This avoids the need to use multiple scans to create a composite value, and provides results at the end of each scan.

The TDi Measurement and Control System has been developed for the control - and fine tuning of the feedback loop - of parameters such as coater roll gap or CD tilt, die lip position or pump speed, helping users achieve consistent product across the web. The available RemoteView™ software provides valuable diagnostic data for the process manager, even when away from the factory or office, via the internet.

Systems are also available for the extruders of the separator film to ensure smooth, fault-free product with tightly controlled thickness. NDC's leading edge near infrared (NIR) sensor technology provides direct thickness measurement of the separator film with unrivalled accuracy.

NDC Systems replace slow, time-consuming off-line sample testing, freeing up personnel time. Real-time process measurements, with feed-in to the control system, deliver rapid payback through reduced scrap, faster start-up and optimal Li-Ion coating weight. The resulting consistent product performance and long battery life insures customer and supply chain loyalty.