Working principle and structural composition of lithium battery sorting machine

The core operating principle of a lithium battery sorter is based on the precise detection and classification of battery electrical performance parameters. During the lithium battery production process, subtle differences in raw material properties and fluctuations in the production process result in a certain degree of variability in key performance indicators such as capacity, internal resistance, and voltage for each battery. The primary task of a lithium battery sorter is to use high-precision testing methods to screen and sort these batteries according to predetermined standards, thereby providing highly compatible individual cells for subsequent battery pack assembly and improving overall pack performance and stability.

Lithium Battery Sorter Operating Principle

Automatic Loading: An automated loading device, such as a robotic arm, conveyor belt, or vibrating plate, quickly and stably feeds the lithium batteries to the sorter's inspection area. This process requires not only that the loading equipment accurately grasp and place the batteries but also that the batteries be protected from external forces during transport to avoid compromising the accuracy of the test results.

Electrical Performance Parameter Testing: After the batteries enter the inspection area, the sorter utilizes high-precision sensors and professionally designed test circuits to accurately measure various electrical performance parameters. Among these, the most critical parameters include the battery's open circuit voltage (OCV), internal resistance (DCIR), and actual capacity. For example, using the four-probe method to measure battery internal resistance effectively reduces contact resistance errors during measurement, improving accuracy. Battery capacity testing typically employs a constant current charge/discharge method. At specific charge/discharge rates, the battery's charge/discharge time and voltage curves are recorded to accurately calculate the battery's actual capacity.

Data Analysis and Processing: The extensive battery performance data acquired during testing is transmitted in real time to the sorting machine's built-in central processing system. This system utilizes pre-programmed data analysis algorithms and pre-defined sorting criteria to conduct in-depth analysis and evaluation of each battery's data. For example, batteries can be classified into different capacity ranges based on their capacity, or they can be categorized into high-quality, acceptable, or unacceptable grades based on their internal resistance and voltage consistency.

Automatic Sorting and Unloading: Based on data analysis, the sorting machine uses automated mechanical devices, such as sorting robots, pneumatic valves, and chutes, to sort batteries by category into corresponding collection containers or subsequent production processes. For example, batteries with excellent performance and high consistency are precisely delivered to the assembly line for high-quality battery packs, while batteries that do not meet performance standards are sorted into scrap recycling or reprocessing areas.

Lithium Battery Sorting Machine Structure

Loading Module: This module is primarily responsible for automatically feeding the lithium batteries to be sorted into the inspection area. Common loading methods include vibrating plate loading, conveyor belt loading, and robotic arm loading. Vibratory tray loading is suitable for loading small cylindrical batteries. The vibration of the vibrating tray aligns the batteries on a track and allows them to be transported to the next stage in an orderly manner. Conveyor belt loading offers high throughput and stable speed, making it suitable for loading lithium batteries of various shapes and sizes. Robotic arm gripping loading offers high flexibility, enabling precise grasping and placement of batteries of varying specifications, making it particularly suitable for sorting applications requiring high-precision positioning.

Detection module: The detection module is the core component of the lithium battery sorting machine, responsible for accurately measuring various battery electrical parameters. This module is typically equipped with a high-precision voltage meter, internal resistance tester, capacity tester, and various sensors. To ensure accuracy and stability, these test devices often utilize advanced measurement technology and sophisticated circuit design, and undergo rigorous factory calibration and commissioning. For example, some high-end lithium battery sorting machines achieve voltage measurement accuracy of ±0.1mV and internal resistance measurement accuracy of ±0.1mΩ, meeting the requirements for high-precision lithium battery performance testing.

Control Module: The control module acts as the "brain" of the lithium battery sorter, responsible for automated control and management of the entire sorting process. It primarily consists of an industrial computer, a programmable logic controller (PLC), and related control software. Through the programming of specific control programs, the control module precisely coordinates and controls the operations of various parts of the equipment, such as the loading speed of the feeder, the inspection cycle of the detection module, and the sorting actions of the sorting mechanism. The control module also provides data acquisition, storage, and analysis, enabling real-time monitoring of the equipment's operating status and generating statistical reports and analytical charts based on inspection data, providing powerful data support for production process optimization and quality control.

Sorting Module: Based on battery performance data provided by the detection module, the sorting module classifies and sorts batteries according to predetermined standards. Common sorting methods include mechanical sorting and pneumatic sorting. Mechanical sorting typically uses mechanical structures such as manipulators and screw slides to precisely place batteries into corresponding collection containers through precise position control. Pneumatic sorting utilizes compressed air as a power source. By controlling the opening and closing of pneumatic valves, the batteries are guided along different chutes into the corresponding sorting areas under the influence of airflow. The design of the sorting module must fully consider factors such as sorting speed, accuracy, and reliability to ensure efficient and accurate battery sorting.

Unloading Module: The unloading module is primarily responsible for removing sorted batteries from the sorting machine and transporting them to subsequent production processes or storage areas. Unloading methods vary, including conveyor belt unloading, box unloading, and automatic packaging unloading. Conveyor belt unloading is suitable for large-scale production scenarios, enabling continuous and efficient unloading operations. Box unloading facilitates the collection and transportation of batteries in batches and is suitable for applications requiring categorized storage. Automatic packaging unloading allows for simultaneous packaging of batteries while unloading, improving production automation and efficiency.