In lithium-ion battery manufacturing processes, cutting-stacking all-in-one machines serve as core equipment for cell formation. Real-time roll-diameter monitoring of electrode and separator coils directly determines unwinding-tension stability, cutting accuracy and cell yield. Conventional contacttype diameter-measurement methods tend to scratch and contaminate electrodes, failing to meet cleanliness requirements for lithium-battery production.

To address detection requirements for cutting-stacking stations, the U18 series ultrasonic sensors enable non-contact on-line roll-diameter measurement. Based on the ultrasonic detection principle, they are immune to material transparency, surface color, reflection and on-site lighting conditions, and adapt to lithium-battery production environments with dust.

1. Working Principle

The U18 ultrasonic sensor is mounted vertically on the side of the coil of the cutting-stacking all-in-one machine, perpendicular to the coil cross-section. By calculating the distance between the sensor face and the coil surface via the time difference between transmitted and received ultrasonic echoes, real-time signals are uploaded to the control system to compute the current electrode roll diameter. It continuously tracks dynamic reduction of coil size and delivers accurate roll-diameter data for the electronic control system.

Model: U18-D1000IT-R00A

Detection Range: 60-1000mm

2. Key Product Features

· Non-contact Measurement: No physical contact with electrodes or separators, eliminating risks of scratching, powder shedding and contamination, complying with cleanliness standards of lithium-battery production lines.

· Real-time On-line Monitoring: Continuous distance-signal output for dynamic roll-diameter feedback to support closed-loop control.

· One-click Distance Auto-Teach: The grey wire supports detection-distance teach-in for simple commissioning and fast production-line deployment.

· Built-in Temperature Compensation: Counteracts measurement drift caused by temperature fluctuation inside equipment cabinets for long-term data stability.

· Wide-voltage Power Supply: DC 10-30 V, standard industrial power supply for direct connection to automation electronic-control systems.

3. Application Scenarios

Lithium-battery cutting-stacking all-in-one machines; cathode & anode electrode unwinding; separator unwinding; non-contact distance measurement and on-line roll-diameter monitoring for various film and foil coils.

Real-time roll-diameter signals from KRONZ U18 series ultrasonic sensors provide input for unwinding servo closed-loop control to realize constant-tension control and inertia compensation. It also supports residual-material monitoring and fault diagnosis to stabilize production and deliver a reliable roll-diameter-detection solution for lithium-battery cutting-stacking processes.