The high-precision slitting technology of the capacitor film slitting machine has significantly improved the film processing efficiency through various optimizations, and the following is a detailed analysis of its core mechanism and specific advantages:
1. The core technology of high-precision slitting
• Tension control system
Closed-loop tension control (such as magnetic particle brake + tension sensor) is used to control the fluctuation within ±0.1N to avoid film stretching or wrinkling. For example, TERAOKA's PID dynamic adjustment technology can achieve stable tension at a slitting speed of 300 m/min.
• Tooling system upgrades
Using diamond-coated round knives or laser knives, the cutting edge accuracy is ±1μm, and the service life is extended by more than 3 times. KAMPF's "zero backlash" turret design reduces material burrs and ≤± slitting width error of 0.05mm.
• Intelligent web correction system
The photoelectric or CCD sensor monitors the edge position in real time, and cooperates with the servo motor to adjust (response time<10ms) to ensure that the slitting straightness deviation <0.1mm/m, reducing the scrap rate.
2. Specific performance of efficiency improvement
• Speed and yield
While traditional slitter speeds are typically 100-150m/min, high-precision models (such as the Italian ATLAS) can reach 600m/min and increase yield from 90% to 99.5%. Taking the capacitor film production line with an annual output of 5,000 tons as an example, it can reduce waste by 50 tons per year.
• Automation integration
The automatic tool change system (tool change time < 30 seconds) and roll diameter prediction algorithms (e.g., Siemens S7-1500 PLC control) reduce downtime and increase overall equipment effectiveness (OEE) by more than 20%.
• Multi-specification adaptation
Through the preset parameters of HMI HMI (such as slitting width and tension curve), the time to change product specifications is shortened from 30 minutes to 2 minutes, which is suitable for small batch customized production.
3. Effect on film properties
• Edge quality
High-precision slitting < edge roughness (Ra) to 0.2 μm, avoiding edge breakdown during metallization plating, and improving the withstand voltage performance of capacitors (e.g., 15% increase in breakdown voltage).
• Material utilization
By optimizing the knife arrangement scheme (e.g., Nesting algorithm), the material utilization rate has been increased from 92% to 97%, especially for high-value materials (e.g., PP, PET).
4. Industry application cases
• New energy field
After a lithium battery separator manufacturer adopted Brückner's slitting machine, the slitting burr of the 8μm ultra-thin separator was reduced to <5μm, which met the strict requirements of the power battery for the consistency of the separator.
• Optical thin film field
Samsung Displays' brightness enhancement film (BEF) slitting uses high-precision technology to control light transmittance fluctuations within ±0.3%, which is better than the industry standard of ±1%.
5. Future development trends
• Digital twin technology
Predicting slitting parameters (e.g. tool wear models) through virtual commissioning further reduces test losses.
• AI visual quality inspection
In-line inspection systems, such as Keyence laser scanners, reject defective rolls in real time for "zero-defect" delivery.
conclusion
Through the comprehensive effect of hardware upgrading (tools, sensors) and software optimization (control algorithms, AI), high-precision slitting technology can improve the processing efficiency of capacitor film by 30%-50%, and reduce the comprehensive cost by more than 15%, which has become a key link in the upgrading of the film industry. In the future, with the growth of ultra-thinning (<3μm) and the demand for composite films, the importance of this technology will be further highlighted.
