Precision Press-fitting Line for Top Covers of New Energy Power Batteries
In the power battery manufacturing field in 2026, safety and reliability are the core competitive advantages.
A leading battery supplier, when producing top covers for 4680 cylindrical batteries and square aluminum
-cased batteries, faced pain points such as large fluctuations in the pass rate (approximately 3% defect rate)
and lack of data traceability in traditional pneumatic press-fitting stations.
To achieve "lights-out factory" level digital management, the plant introduced a precision press-fitting
module based on the FSKSD-80L intelligent servo electric cylinder, replacing the original pneumatic-hydrau
lic booster cylinder.
I. Core Requirements Analysis
1. Micron-level Depth Control: The compression of the top cover sealing ring must be controlled within
±0.02mm. Excessive depth will damage the sealing ring, while insufficient depth will result in poor sealing
and electrolyte leakage.
2. Synchronous Force and Position Monitoring: Due to the minute tolerances in the aluminum shell thick
ness, relying solely on position control can easily damage the shell. The system must have a real-time monit
oring function for the "pressure-displacement curve".
3. High-frequency continuous operation: The production line cycle time is 1.5s/pcs, requiring the drive mech
anism to operate at high speed 24/7 with minimal heat dissipation.
II. Technical Performance of FSKSD-80L in this Case Study
1. "Digital Muscle" under Closed-Loop Control
In this case study, the FSKSD-80L electric cylinder, in conjunction with the Huichuan SV680 series servo drive,
achieves true full closed-loop positioning through a high-resolution encoder.
• Flexible Contact: When approaching the workpiece, the electric cylinder switches from fast-forward to
slow-speed flaw detection mode to avoid damage to the aluminum shell from hard impacts.
• Precision Pressing: Utilizing its 80mm high-thrust characteristic, it presses down uniformly at a constant
speed during the last 2mm of the stroke, ensuring uniform force on the sealing ring.
2. "Pressure-Displacement" Envelope Determination
The FSKSD-80L incorporates a high-dynamic-response current loop control. Based on torque data fed back
from the drive, the system generates a press-fit curve in real time.
• Online Monitoring: If the curve exceeds the preset "safety envelope" (e.g., pressure rises prematurely,
indicating component misalignment), the system will shut down immediately within 10 milliseconds.
• Quality Traceability: The pressing data for each battery (maximum pressure, final depth, pressing time) is
uploaded to the factory's MES system in real time via EtherCAT bus, achieving true "one-click traceability."
3. Seamless Integration of Modular Orthogonal Structure: As the execution end of a Programmable Multi-
module Orthogonal system, the FSKSD-80L's compact body makes it easy to install on the Z-axis. Its 80L
model features a long-life ball screw, ensuring that repeatability remains at its factory state even after one
year of continuous operation (approximately 5 million cycles).
III. Project Implementation Results (Actual Measurement Data in 2026)
• Leap in Pass Rate: The first-pass pass rate increased from 97% to 99.98%, essentially eliminating the risk
of leakage caused by inconsistent pressing depth.
• Reduced Energy Consumption: By eliminating the air compressor station, energy consumption per work
station was reduced by 65%, meeting the 2026 industrial carbon neutrality emission standards.
• Flexible Changeover: When changing to different battery top covers, workers only need to retrieve the "re
cipe" on the HMI interface, and the electric cylinder automatically adjusts its stroke, reducing changeover
time from 2 hours to 10 seconds.
IV. Case Summary In this case, the FSKSD-80L is not only an actuator but also a "precision quality inspector"
on the production line. It demonstrates that in precision manufacturing in 2026, replacing pneumatic/hydra
ulic cylinders with electric cylinders is not a simple power switch, but a leap from "fuzzy processing" to "qu
antitative manufacturing." For companies seeking to upgrade their punch presses with automated feeding
or precision assembly, the FSKSD-80L offers a cost-effective and highly reliable standardized solution.
