Atonm Laser Sensor Case | Battery Production (Stacking | Winding) Diaphragm Roll Remaining Material Detection Solution

Project Background:

A Dongguan stacking machine manufacturer produces high-speed Z-type stacking machines commonly used in the new energy industry. During operation, the PLC monitors diaphragm roll remaining material and notifies operators to replace the roll when material is low, avoiding idle running.

The customer previously estimated remaining material by counting servo motor rotations, but variations in winding thickness caused large deviations. Therefore, the customer added an sensor solution to measure film thickness synchronously.

(Z-type stacking machine)

Project Goal: Detect diaphragm roll remaining material and alert on empty rolls to avoid idle running.

Challenges:

Long detection distance: the diaphragm roll core is mainly 3-inch and the roll diameter can reach 250mm, requiring a sensor with relatively long detection range.

Non-contact detection: the diaphragm material is fragile and requires non-contact measurement to preserve integrity.

(Diaphragm roll core)

Solution:

(Atonm LD1-H400 Laser Sensor)

The solution uses the Atonm LD1-H400 Laser Sensor, mounted inside the base and oriented to measure the diaphragm roll outer layer thickness. By measuring the outer layer thickness, the system calculates remaining roll material. When thickness approaches the minimum threshold, the PLC notifies operators via the HMI to prepare a replacement roll.

The LD1-H400 Laser Sensor provides high accuracy, long measurement range, stability, and simple operation. It supports non-contact measurement for metals and plastics, has a very small probe for compact installation, and can communicate real-time data to external equipment to help improve production efficiency.