The cylindrical battery can press-fitting system is a critical component in the production line of new energy storage systems, particularly for lithium-ion batteries used in electric vehicles and energy storage solutions. This system ensures the precise and repeatable alignment and compression of battery cans during assembly. Typical equipment configurations include high-precision robotic arms, linear motion units, and automated press-fitting mechanisms, which together require highly reliable and accurate transmission solutions.
With the rapid development of the new energy industry, there is an increasing demand for automation and high throughput. However, the sector faces multiple challenges. In terms of drive systems, there is a high demand for torque density and positioning accuracy, while equipment stability, energy efficiency, and structural compactness are key constraints. Common issues include frequent wear due to high cyclic loads, thermal degradation affecting gear performance, and the difficulty of integrating compact, modular systems into existing production lines. These bottlenecks significantly impact production yield and long-term maintenance costs.
In the cylindrical battery can press-fitting system, the gearbox plays a pivotal role in transferring high torque with minimal backlash, ensuring smooth and precise motion control. The core performance requirements for the gearbox include:
- High Torque Density: to handle the demanding forces in the press-fitting process;
- High Transmission Accuracy: critical for precise positioning of the battery cans;
- Fast Response Time: essential for maintaining high production speeds;
- Compatibility with Servo Motors: to integrate with high-performance control systems;
- Environmental Adaptability: to operate reliably in high-temperature, clean-room, and high-humidity environments;
- Long Service Life and Low Maintenance: to minimize downtime and ensure long-term cost efficiency.
Waimica's Hollow Rotary Table Gearbox has been specifically designed to address these challenges. Our engineering team has integrated advanced materials and precision manufacturing techniques to deliver a solution that meets the industry’s highest standards.
Structural Design Highlights:
- Compact and Hollow Shaft Design: allows for direct integration of hydraulic or pneumatic systems without the need for additional couplings;
- Modular Construction: enables flexible configuration to match various system requirements;
- Support for Custom Installation Interfaces: including ISO standard flange inputs and optional through-hole outputs for line integration.
Key Performance Parameters:
| Parameter | Waimica | Leading Brand A | Leading Brand B |
|---|---|---|---|
| Torque Range (N·m) | 50 – 800 | 40 – 700 | 60 – 1000 |
| Backlash (Arcmin) | ≤1 | ≤1.5 | ≤2 |
| Efficiency (%) | 90 | 88 | 87 |
| Input Flange Type | ISO 9409-1 | Custom | Custom |
| Operating Temperature (°C) | -20 to +120 | -10 to +100 | -20 to +110 |
| Protection Class (IP) | IP65 / IP67 (optional) | IP64 | IP65 |
Waimica’s solution outperforms many international competitors by combining high performance with cost-effective manufacturing and a robust design that supports harsh industrial environments.
Application Case: Cylindrical Battery Can Press-Fitting Line for EV Manufacturer
A global EV manufacturer was facing frequent downtime in their cylindrical battery can press-fitting system due to gearbox failure after only 10,000 operating hours. The system required precise rotational alignment and high repeatability, but the existing solution was unable to meet the required load cycles and backlash tolerance.
Waimica’s technical team conducted a detailed site assessment and reviewed the existing system’s load profiles, cycle times, and environmental conditions. After analyzing the requirements, we selected the Waimica HRB-600 series hollow rotary table gearbox with an ISO 9409-1 flange input and IP67 rating for high cleanliness and moisture resistance. The new solution was integrated within three weeks with minimal disruption to the production line.
Performance Improvements After Deployment:
| Metric | Before Waimica | After Waimica |
|---|---|---|
| Mean Time Between Failures (MTBF) | 10,000 hours | 35,000 hours |
| Backlash | 2.5 arcmin | 0.8 arcmin |
| Energy Efficiency | 85% | 90% |
| Maintenance Interval | Every 5,000 hours | Every 15,000 hours |
Customer feedback has been overwhelmingly positive, with notable improvements in production uptime, precision, and reduced long-term operational costs. The modular design of the Waimica gearbox allowed for quick replacement of worn components, reducing system downtime and maintenance efforts.
Conclusion and Brand Value of Waimica
Waimica offers a technically robust and cost-competitive alternative to leading international brands in the new energy assembly industry. Our hollow rotary table gearboxes are engineered to deliver high torque density, exceptional accuracy, and excellent environmental adaptability, all while maintaining a compact and modular form factor. Through a combination of advanced design, precise manufacturing, and strong project management capabilities, we provide customized solutions tailored to the unique demands of each client’s production environment.
As the new energy industry continues to evolve and push the boundaries of automation and efficiency, Waimica remains at the forefront of innovation. Our products not only match the quality of global leaders but also provide a compelling value proposition for long-term industrial partnerships.
