Application Case of Atonm MDSC-2100L in Thin Material Detection for Lithium Battery Stacking Machines

I. Customer Background and Industry Pain Points

A high-tech enterprise in the new energy sector, specializing in the R&D, manufacturing and sales of automated lithium battery equipment. Its products cover the full-process equipment for lithium battery production, and it holds a significant market share especially in the niche segment of stacking machines. In the lithium battery pole piece stacking process, it is necessary to conduct accurate multi-layer detection on copper foils and aluminum foils as thin as 0.01mm (1 hundredth of a millimeter) to ensure that the number of pole piece layers complies with process requirements. Additionally, the customer requires the function of detecting copper-aluminum mixed materials. The ultrasonic sensors and through-beam magnetic induction double-sheet detectors previously adopted by the enterprise can no longer meet the needs of the new production line.

II. Detection Requirements and Technical Challenges

Core Detection Requirements

Material Characteristics: The detection targets are copper foils and aluminum foils with a thickness of 0.01mm. It is necessary to distinguish between single-sheet and multi-layer states, as well as identify the presence of mixed materials.

Limited Installation Space: The internal structure of the stacking machine is compact. Traditional sensors are relatively large in size, making it difficult to fit into narrow installation positions and resulting in challenges in the layout of detection stations.

Bottlenecks of Traditional Solutions

Both ultrasonic sensors and through-beam magnetic induction double-sheet detectors require paired installation of transmitting and receiving ends, which occupy double the space. Moreover, they cannot effectively distinguish copper-aluminum mixed materials.

III. Customized Solution: Atonm MDSC-2100L Compact Single-probe Metal Double-sheet Detector

Core Advantages of the Solution

To address the customer's pain points, we recommend the Atonm MDSC-2100L Compact Single-probe Metal Double-sheet Detector, whose technical features precisely match the requirements:

Ultra-compact Design

The probe measures only 12×35mm, supporting embedded installation. It can be directly integrated into the end of the stacking machine's robotic arm or the narrow gaps of the silo, reducing the installation space occupation by 60% compared with traditional solutions.

The single-probe structure eliminates the need for a through-beam counterpart, simplifying equipment layout and adapting to extreme installation environments with apertures ≤20mm.

High-sensitivity Detection

Customized high-frequency eddy current detection technology, with an exclusive algorithm developed for ultra-thin metal sheets of 0.01mm grade, capable of identifying the inductance difference between single-sheet and multi-layer sheets (with a resolution of up to 0.1μH).

Built-in temperature compensation module that automatically calibrates the impact of ambient temperature drift on detection accuracy, ensuring consistent detection performance for both copper and aluminum materials.

Ultra-fast Response Performance

Adopting a high-speed conversion chip, the detection response time is as low as 50ms, fully matching the high-speed production rhythm of 300 cycles per minute of the stacking machine.

Supporting RS485 output mode, it seamlessly connects to the equipment's PLC control system, realizing real-time upload of layer count data and abnormal alarm.

Equipped with Recipe Storage Function

The MDSC-2100L is equipped with a 100-set recipe storage function for storing and managing parameters of various materials. The host computer can quickly switch between different metals to be detected, eliminating the hassle of repeated debugging and significantly improving production efficiency.

Customer Core Feedback

Space Compatibility

"The compact probe design perfectly solves the installation challenge between the internal shaft systems of the stacking machine. No modification to the existing mechanical structure is required, and the installation time is reduced from 4 hours to 30 minutes."

— Equipment Engineer

Detection Stability

"During high-speed stacking at 300 cycles per minute, it can accurately distinguish between single aluminum foil sheets and double-layer stacks. The defective rate of pole piece layer counts has dropped from 0.8% to 0.03%, significantly reducing rework costs in subsequent processes."

— Production Supervisor

V. Solution Value

Core Values

Upgraded Quality Control

By accurately identifying the layer count of ultra-thin metal sheets down to 0.01mm, it eliminates layer-count defects in the stacking process at the source, helping the customer achieve the process target for lithium battery pole piece yield.

Optimized Equipment Integration

The compact design frees up internal space in the stacking machine, reserves interfaces for future equipment miniaturization and lightweight upgrades, and adapts to the precision development trend of 3C lithium battery production lines.

Remarkable Cost-effectiveness

Compared with imported counterparts, the MDSC-2100L solution reduces costs by 40% while delivering superior overall detection performance, achieving the cost-performance advantage of domestic substitution.

Industry Application Expansion

This solution can be replicated for the welding process in lithium battery production. Its characteristics of compact size, high sensitivity and ultra-fast response provide an innovative detection approach for industries with stringent space and precision requirements, such as 3C electronics and precision metal processing.

Conclusion

The Atonm MDSC-2100L Compact Single-probe Metal Double-sheet Detector, through customized design, has successfully addressed the dual challenges of space constraints and performance requirements for ultra-thin material detection in lithium battery stacking machines, establishing itself as a benchmark solution for high-precision detection in compact scenarios. As the new energy industry continues to raise its requirements for manufacturing precision, such specialized and scenario-specific intelligent sensors will play an increasingly important role, helping domestic automated equipment achieve technological breakthroughs.