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Production lines

Battery & Energy Equipment Manufacturing

Synchronised lines that wind and stack thin foil at constant tension.

  • Typical axes3
  • NetworkEtherCAT
  • Control modeCST · CSP
  • Recommended seriesSDU3 · SMR · SD24-LP · SM06
Start Product Selection See the solution
01
The sector at a glance

Battery & Energy Equipment Manufacturing

Electrode winding, stacking and cutting stations handle thin material at constant tension and with high repeatability.

Three things that decide it on the shop floor

  1. 01

    Tension

    The torque reference follows the changing roll diameter.

  2. 02

    Flying cut

    The cutter axis locks electronically to web speed.

  3. 03

    Repeatability

    Fast settling and good tuning decide the stack.

02
Our advantages

Why SMB TECHNICS?

One set, controller to cable

Controller, drive, motor, cable and connector arrive checked against each other; interface problems are solved at the desk, not on the shop floor.

Open standards

EtherCAT, CANopen, Modbus RTU, CODESYS and CiA 402: your machine is not tied to a closed ecosystem.

Engineer-to-engineer support

The same team from sizing to commissioning, on site and remotely.

Documented products

Manuals, CAD, ESI/EDS and firmware in the Document Centre; every product you choose comes with its documents.

Our application know-how for this sector
  • Tension control across a changing roll diameter
  • Flying cut synchronised to web speed
  • Fast-settling tuning for stacking
03
How we build the system

From control chain to commissioning, which product goes where

3.1

The control chain and the recommended products

How the machine is driven and the SMB products we choose for it.

In battery cell and energy equipment production, electrode winding, stacking and cutting stations have to handle thin, delicate material at constant tension and with high repeatability.

Thin electrode foil forgives nothing: tension, synchronisation and repeatability all have to be right at once.

The control chain

Winding and stacking lines are driven in sync from a MAT-LC CODESYS CPU over EtherCAT. Unwind and rewind axes run in torque mode, feed and cutting axes in synchronous position mode; SD24-LP and SDU3 drives with low-inertia SMR motors carry that motion.

What decides the result

  • Tension. As the roll diameter changes, so does the torque needed for the same tension; the controller computes the diameter and updates the torque reference.
  • Flying cut and sync. Cutting a moving web without stopping it needs the cutter axis locked electronically to the web speed.
  • Repeatability. In stacking every layer has to land on the same point; fast settling and good tuning decide it.

Sizing it

We need the largest and smallest roll diameter, web width and tension, line speed and station cycle. The selection guide picks the drive and the sizer the motor.

Select the products for this machine Enter power, torque and network; compare compatible drives and motors and add them to your basket. Selection guide
3.2

The architecture: which product goes where

The boxes show the real products; click one to open the series.

EtherCAT Operator panel HMI-R9 Controller · CODESYS MAT-LC CPU I/O and sensors MAT-LC I/O · PNP / NPN Safe stop STO · brake Supply protection EMI · braking resistor Electrode unwind / rewind Drive · SDU3 CST · EtherCAT Motor SMR Feed and cut Drive · SD24-LP CSP · EtherCAT Motor SMR Stacking (pick & place) Drive · SD24-LP CSP · EtherCAT Motor SM06
  • EtherCAT
  • Ethernet
  • Power and feedback
  • Safety
Where this machine sits on the full SMB system map
CPU / PLC & Motion Control 3 series Expansion Rack / IO 10 products Ethernet switch Ethernet Operator Panels 3 series Sensors 3 series EtherCAT Servo Drives 17 products CANopen Servo Drives 6 products Modbus RTU Servo Drives 4 products Servo Motors 6 series Power and Encoder Cables 2 series CODESYS IEC 61131-3 PLCopen Motion Control CiA 402 Drive profile
EtherCAT Ethernet CANopen Modbus RTU Digital I/O Power and feedback

CPU / PLC & Motion Control

Expansion Rack / IO

Ethernet switch

The industrial switch distributes Ethernet traffic between the controller, the operator panel and the engineering PC. It is part of the architecture, not part of the SMB catalogue.

Operator Panels

Sensors

EtherCAT Servo Drives

CANopen Servo Drives

Modbus RTU Servo Drives

Servo Motors

Power and Encoder Cables

CODESYS

SMB controllers are programmed in CODESYS: the IEC 61131-3 languages, integrated motion and a single project covering both machine logic and the axes.

PLCopen

PLCopen Motion Control function blocks give every axis the same standard interface, so proven machine code carries over from one project to the next.

CiA 402

SMB servo drives implement the CiA 402 drive profile: the same state machine and the same operating modes over EtherCAT and over CANopen.

3.3

Product placement, axis by axis

Each axis, its task, its control mode and the drive–motor pair on it.

  1. 01
    Electrode unwind / rewind Winding at constant tension
    CST · EtherCAT
    SDU3 Drive SDU3 Series Three-phase 380 V AC EtherCAT servo drives with power steps from 400 W to 7.5 kW. SMR Motor SMR Series Low-inertia servo motors in 60–130 mm frames, single-phase 220 V AC and three-phase 380 V AC, 400 W–7.5 kW, with BiSS absolute encoders.
  2. 02
    Feed and cut Flying cut without stopping the web
    CSP · EtherCAT
    SD24-LP Drive SD24-LP Series Flagship EtherCAT low-power servo drive line. SMR Motor SMR Series Low-inertia servo motors in 60–130 mm frames, single-phase 220 V AC and three-phase 380 V AC, 400 W–7.5 kW, with BiSS absolute encoders.
  3. 03
    Stacking (pick & place) Placing each layer on the same point
    CSP · EtherCAT
    SD24-LP Drive SD24-LP Series Flagship EtherCAT low-power servo drive line. SM06 Motor SM06 Flange Family 60 mm-frame 220 V AC servo motors, 200–400 W, with absolute, BiSS and incremental encoder options and an optional brake.

CSP: cyclic synchronous position · CSV: cyclic synchronous velocity · CST: cyclic synchronous torque · PP: profile position. The series is confirmed by load and supply voltage.

3.4

The build, step by step

From requirement to support; the SMB products and tools each step uses.

  1. 1

    Requirements and sizing

    The motion profile, load and cycle time of every axis are collected; torque, speed and inertia ratio are calculated per axis.

    • Peak and RMS torque, top speed
    • Load-to-motor inertia ratio and gearing
    • Supply: 220 V AC, 380 V AC or 24–70 V DC
    Sizer Selection guide
  2. 2

    Architecture and product choice

    The network (EtherCAT, CANopen, Modbus RTU), the controller and the drive–motor pair per axis are chosen; the safety and power side is drawn at this step.

    • EtherCAT for synchronised axes, CANopen for independent ones
    • Drive current covers the motor peak current
    • STO and braked motors come from the risk assessment
    SD24-LP-04-D1-E MAT-LC-C06 MATSPS1M8-350P4NOC MAT-SMR10-JS-D540S30-MT16ST23-200B0
  3. 3

    Cabinet, cabling and EMC

    Power and encoder cables run in separate ducts with their shields bonded 360°; an EMI filter goes at the drive input and a braking resistor where the load regenerates.

    • Flexible cable for the cable chain
    • Shields are earthed at both ends
    • The braking resistor is sized from the braking energy
    Power / Motor Cables Encoder Cables SMKP Power Connectors SMKE Encoder Connectors EMI Filters Braking Resistors
  4. 4

    Software and network

    In the CODESYS project the axes are defined with PLCopen blocks; the drives join the network through their ESI/EDS files and run the CiA 402 state machine.

    • IEC 61131-3 languages and PLCopen Motion Control
    • ESI (EtherCAT) and EDS (CANopen) in the Document Centre
    • EtherCAT coupler for remote I/O
    MAT-LC CodeSys CPU MAT-LC I/O Modules MAT-LC System Modules
    CODESYS FAQ Document centre
  5. 5

    Commissioning and tuning

    After wiring and direction checks the gains are tuned and the axes homed; the operator panel carries the machine recipes.

    • Direction, limit and emergency-stop tests
    • Speed and position loop gain tuning
    • Backing up the parameter sets
    HMI-R9 Series
    Commissioning FAQ Troubleshooting
  6. 6

    Support and lifecycle

    Alarm codes, spare parts, firmware and training, from the same engineering team.

    • Alarm-code and troubleshooting guides
    • Manual, CAD and firmware downloads
    • Remote and on-site support
    Technical support Document centre
3.5

The solution package: what comes with the product

Hardware, software, engineering and lifecycle.

02

Software and know-how

The CODESYS project, PLCopen motion blocks and know-how specific to this machine.

  • Tension control across a changing roll diameter
  • Flying cut synchronised to web speed
  • Fast-settling tuning for stacking
03

Engineering support

Sizing, architecture, commissioning and tuning, on site and remotely.

  • Motor and drive sizing per axis
  • System architecture and network choice
  • Commissioning, gain tuning and homing
04

Lifecycle

Manuals, ESI/EDS files, spare parts and training.

  • Document Centre: manuals, CAD, firmware
  • ESI and EDS files, parameter backups
  • Spare parts and user training
Engineering knowledge base

Commissioning this application

The topics engineers in this industry ask about most, each with answers, checklists and troubleshooting steps.

EtherCAT CODESYS Analog control Servo commissioning & tuning

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