Yokogawa markets solutions in the field of industrial automation (IA) and control under the OpreX brand. According to Yokogawa, the name OpreX stands for excellent technologies and innovations that the company develops by creating shared value with its customers, and it encompasses the entire range of the Japanese company's IA products, services and solutions. The OpreX Quality Control System division also includes coating thickness measurement systems. Yokogawa is now launching an optimized version of the OpreX Battery Web Gauge ES-5 that is more compact, better protected and encapsulated, more energy efficient and, thanks to a special servo drive, optimized for maximum throughput and accuracy.

Continuous further development

Since the introduction of the first online layer thickness gauge for coating lines in 1962, Yokogawa has built up a strong market position and continuously developed its measuring system. The measuring system is used in the final processes of production lines to continuously measure and control the thickness, weight, color and other properties of materials such as paper and film. One of these products is WEBFREX3ES, which was developed for the production of electrode foils for lithium-ion and other battery types. It has been used in battery production worldwide for decades. As the demand for rechargeable batteries increased with the global shift to electric vehicles, and in parallel with this trend, battery manufacturers also had to reduce the CO2 emissions of their production processes while improving productivity in an increasingly price-competitive market, ES-5 was developed to meet these requirements while maintaining all the functions of WEBFREX3ES.

Precise measurement of the coating on copper and aluminum foils

Yokogawa's measurement principle for the battery industry offers long-term stability and a constant measurement source. The use of the same parts for anode and cathode lines simplifies spare parts management. The measurement principle is designed to provide precise measurement of the coating on copper and aluminum foils and to offer a low total cost of ownership in the areas of performance, throughput and maintenance compared to other methods.

Reducing CO2 emissions

The box frame used for the OpreX Battery Web Gauge ES-5 reduces power consumption by more than 50 percent, weighs 75 percent less, and reduces air consumption volume by 90 percent compared to the WEBFREX3ES, according to Yokogawa. This reduces CO2 emissions in the battery production line and supply chain.

Link to peripheral processes

The OpreX Battery Web Gauge ES-5 uses the OpreX Collaborative Information Server as a central platform for information management. The platform collects data from equipment and systems used in various peripheral processes. This is to ensure that an even coating is applied to the electrode sheets, which is critical to the performance and quality of rechargeable batteries. By linking to peripheral processes, Yokogawa says production efficiency is increased and optimization of the entire production line, rather than individual processes, is made possible.

Safe quality monitoring

Like the WEBFREX3ES, the OpreX Battery Web Gauge ES-5 offers a safe design that is said to minimize fire risks in rechargeable batteries. This is achieved by reducing exposure to copper and metal powder. It has a fast scanning speed of three seconds at a width of 1,500 millimeters. With up to 1,600 measuring points per width and a minimum spot measurement of five millimeters, quality control is more precise. The new sensor design and the box-shaped frame with a safety cover are also designed to reduce the risk of contact. Greater safety is achieved because the radiation-controlled area is less than half the size of the WEBFREX3ES.

Development based on the system-of-systems approach

“In view of the trend towards electric vehicles, we have developed this online thickness gauge for battery electrode sheets that uses the Collaborative Information Server as its system platform,” explains Hiroshi Tanoguchi, Vice President of Yokogawa Electric. “The development was based on the system-of-systems approach, in which a number of independently operated and managed systems are linked together to form a larger system. The result is a product that saves energy and improves quality, health, safety and the environment for our customers. By providing such solutions, Yokogawa is helping its customers improve profitability and achieve their ESG management goals.”

Video