Optimise lithium battery manufacturing with high precision SCR power controllers | Fuji Electric (2024)

Rapidly expanding market for electric vehicles and renewable energy storage systems

The market for lithium-ion and lithium iron phosphate batteries is at the heart of current technological innovation, fuelling a range of booming sectors.The high energy density and enhanced performance of a lithium battery make it a top material and key industrial innovation, particularly for electric cars and renewable energy strorage systems. These batteries are designed to meet specific requirements, such as extended range and high energy efficiency.
By the way, lithium-ion batteries are not to be confused with li-ion battery or lithium-ion battery cell (also called li ion cells), which are used for domestic purposes.

The energy transition underway around the world, encouraged by carbon neutrality targets, is driving strong growth in demand for lithium-ion battery. In Europe, for example, the European Commission has set the target of banning the sale of combustion-powered cars by 2035, prompting the automotive industry to turn massively to research and development (R&D) of high-performance electrical technology for vehicles and energy storage. The lithium-ion battery is characterised by its long life, low self-discharge rate and low maintenance requirements, making it ideally suited to electric car batteries and renewable energy storage systems.

In addition, the lithium-ion battery is crucial to reducing the carbon footprint of energy storage technologies, thanks to its energy efficiency and recycling potential. This makes it not only a logical choice for manufacturers seeking to meet environmental standards, but also a sustainable solution to support and lead the global energy transition.

Strict environmental requirements

This development is driving an exponential increase in the manufacture of lithium-ion batteries, estimated to reach a global market of USD 129.3 billion by 2027, up from USD 54.4 billion in 2023. However, this rapid expansion is not without its challenges. Battery factories not only have to increase their production capacity, but also guarantee the irreproachable quality of their batteries to meet the huge demand for batteries, as well as the safety and performance requirements of consumers. What's more, as energy costs rise and environmental safety regulations tighten, it's becoming crucial to develop energy-efficient processes.

However, the design of these ultra-thin battery films requires exceptionally precise thermal regulation. The slightest fluctuation in temperature can lead to defects in the films, such as variations in thickness or structural irregularities, which in turn can cause short-circuits in the batteries.

Manufacturers are faced with the need to control the temperature perfectly throughout the manufacturing process of each battery. However, this need for precision often comes up against energy constraints. At a time when energy prices are rising and companies are increasingly subject to targets for reducing their carbon footprint, it is imperative to minimise energy consumption while maintaining optimum battery quality.

As a result, the lithium-ion battery industry not only needs solutions that offer highly accurate measurement and control technology but also solutions and materials that are reliable, energy-efficient, and capable of being easily integrated into large-scale battery manufacturing processes, particularly in the critical stages of electrode manufacturing and cell assembly.

The Power controller with communication functions - APR-V and the Power controller - APR-D are specially designed to provide ultra-precise temperature control, essential for the production of high-quality batteries separator films.
Fuji Electric's power controllers are distinguished by their ability to manage power ramp-up progressively by measuring and fine-tuning the phase angle of the machine and AC power supply. This approach avoids the thermal shocks that can occur with traditional control systems.

By integrating these regulators into the extrusion process used to produce diaphragm seals ultra-thin films, manufacturers can guarantee uniform temperature distribution, an essential quality for maintaining film uniformity and preventing structural defects.

APR-V Power Controller:

Versatility and precision for demanding environments

• Built-in high accuracy feedback function and high temperature control accuracy
• Compatible with three-phase, four-wire circuits
• Energy display and communication function options
• Space and wiring savings
• System construction with Fuji Electric temperature controller series PXF

APR-D power controller :

Compact solution for simplified integration

• Easy to use and adjust thanks to the included adjustment screen
• Simple functions and low maintenance
• Soft start, soft rise and soft fall
• Energy display and communication function options
• System construction with Fuji Electric temperature controller series PXF