Dongguan, Guangdong, China. Tel: +8613528640058 woobin3301@gmail.com

Waimica case

Waimica's Right Angle Gearbox Solution for Cylindrical Battery Can Stamping Systems

2020-01-02 Waimica

Industry Challenges and Pain Points Analysis:

The cylindrical battery can stamping system is a critical component within the electric vehicle (EV) battery assembly sector. These systems are typically used to form and press-fit battery cans, ensuring high precision, stability, and repeatability to meet the increasingly demanding standards of battery manufacturing. The industry is witnessing rapid growth due to the surge in EV production and the adoption of higher energy density battery designs, which require tighter tolerances and more robust automation solutions.

Common components of such systems include robotic arms, hydraulic or pneumatic actuators, and high-precision presses. However, the reliance on traditional transmission systems often leads to several operational bottlenecks:

  • Low Torque Density: Inadequate output torque limits the system’s ability to perform high-force stamping operations efficiently.
  • Reduced Stability: Vibration and backlash in gearboxes can lead to misalignment in the stamping process, affecting product quality and tooling longevity.
  • Energy Inefficiency: High energy consumption of existing transmission systems increases operating costs and reduces overall equipment efficiency (OEE).
  • Space Constraints: The need for compact and modular designs is essential to accommodate high-density production lines and reduce system footprint.
  • Environmental Demands: In cleanroom and high-temperature environments, traditional gearboxes may not provide the required dust resistance, thermal stability, or lubrication performance.

The Role and Technical Requirements of Gearboxes in the Industry:

In cylindrical battery can stamping systems, gearboxes serve as the core transmission component, enabling precise and repeatable motion control. These systems demand gearboxes that meet the following key technical requirements:

  • High Torque Density: To handle the high forces required during stamping and forming processes.
  • High Precision and Low Backlash: Ensuring dimensional accuracy of the battery cans and consistent press alignment.
  • Fast Response Speed: Enabling rapid acceleration and deceleration for high throughput in assembly lines.
  • Compact Design and Right Angle Orientation: Supporting integration into space-constrained production layouts and mechanical arms.
  • High Transmission Efficiency: Reducing energy loss and improving system sustainability.
  • Environmental Adaptability: Maintaining performance under harsh conditions, including high temperatures and cleanroom environments.
  • Long Lifespan and Low Maintenance: Minimizing downtime and ensuring consistent performance over extended operation cycles.

Waimica's Right Angle Gearbox Solution:

Waimica’s right angle gearboxes are specifically designed to meet the unique demands of cylindrical battery can stamping systems. Our solutions directly address the industry’s key challenges with the following innovations:

  • Compact and Modular Structure: Our gearboxes are engineered for minimal footprint, enabling seamless integration into existing robotic and press systems. The modular design allows for flexible adaptation to various application requirements.
  • Right Angle Output: Perfectly suited for integration into robotic joints and multi-axis presses, ensuring space-efficient and flexible system layouts.
  • High Torque and Precision: Delivering consistent high torque output (up to 1000 Nm) with backlash less than 3 arcmin, ensuring reliable and accurate operation.
  • High Efficiency and Low Energy Consumption: With an efficiency rate above 92%, Waimica gearboxes contribute to lower overall system energy usage and improved OEE.
  • High IP Rating and Environmental Compatibility: Rated IP65 to IP67, they are suitable for both high-temperature and cleanroom environments. Special coatings and sealed lubrication systems ensure long-term reliability and contamination resistance.
  • Customization and Quick Delivery: Waimica supports customized input flanges, mounting options, and torque configurations to meet specific system requirements, with a delivery time of less than 4 weeks for most standard and custom models.

Below is a summary of the key technical parameters of Waimica’s right angle gearboxes for cylindrical battery can stamping applications:

Parameter Value
Input Flange Type ISO 9409-1, IEC 693-1, Custom
Output Configuration Right Angle Output (Shaft or Hollow)
Torque Range 100 - 1000 Nm
Backlash < 3 arcmin
Efficiency > 92%
IP Rating IP65 - IP67
Operating Temperature Range -20°C to +80°C
Mounting Options Flange Mount, Foot Mount, Hollow Shaft
Material Aluminum Alloy (6061-T6), Stainless Steel (Optional)

Conclusion and Waimica Brand Value:

Waimica has demonstrated a deep understanding of the technical and operational challenges faced in cylindrical battery can stamping systems. By delivering high-performance, compact, and reliable right angle gearboxes, Waimica not only supports the evolving automation needs of the EV battery industry but also offers a cost-effective alternative to imported components.

Our gearboxes are characterized by:

  • High precision and low backlash;
  • Compact and modular design for easy integration;
  • Excellent environmental adaptability (IP67, high temperature resistance);
  • Customization and fast delivery capabilities;
  • Long service life and low maintenance frequency.

As the EV battery manufacturing industry continues its automation journey, Waimica remains committed to delivering innovative, high-quality, and scalable solutions. We are a trusted partner in providing value-driven, next-generation transmission systems for the global manufacturing sector.