a new concept for small plate manufacturing process · 2017-10-06 · presentation outline 2 •...
TRANSCRIPT
A New Concept for Small Plate
Manufacturing Process
Marcello Fantoni
Sovema Group S.p.A. Sales Director
1
PRESENTATION OUTLINE 2
• Sovema Group S.p.A. Structure and Lead-Acid Product Offer
• Global Lead-Acid Consumption and Focus on Asian Markets:
• 2-Wheel Applications
• Sovema’s Strategy and Solutions for Small Plate Manufacturing:
1. Cast & Punch Grid Production Line CW 320/14
2. E-Bike: Small Plate-Pasting Line
3
Market by
ChemistryLead-Acid Energy Storage Lithium-Ion Energy Storage
ApplicationsLead-Acid Battery Manufacturing:• SLI/AGM Batteries• Motive Power/Truck Batteries• Stationary Power/Industrial Batteries
Li-Ion Cell & Battery Manufacturing:• Prismatic Cells• Pouch Cells• Modules & Packs
Brands
Products
& Solutions
Production
Equipment
for all MFG
Phases
Formation
Equipment Testing
Equipment
Production
Equipment
for Cell,
Module &
Pack
Assembly
Formation
Equipment
Testing
Equipment
MARKETS, BRANDS, AND PRODUCTS
4
• Headquarters: Villafranca di Verona, Italy
• Strong commercial worldwide presence
• Production facilities: Italy, United States, and China
BITRODE
CORPORATION
Saint Louis
Missouri - USA
SOVEMA GLOBAL
SERVICES Inc.
Saint Louis
Missouri - USA
SOVEMA GROUP S.p.A.
Villafranca di Verona
(VR),
ITALY
SOLITH WORKSHOP
Casalecchio di Reno
(BO), ITALY
SOVEMA TIANJIN
BATTERY
EQUIPMENT Ltd.
Tianjin, CHINA
WORLD PRESENCE
5
OXIDE
PRODUCTION
GRID MAKING
MIXING &
PASTING
CURING
ASSEMBLY
FORMATION
FINISHING
PRODUCTION PROCESS OVERVIEW
PRESENTATION OUTLINE 6
• Sovema Group S.p.A. Structure and Lead-Acid Product Offer
• Global Lead-Acid Consumption and Focus on Asian Markets:
• 2-Wheel Applications
• Sovema’s Strategy and Solutions for Small Plate Manufacturing:
1. Cast & Punch Grid Production Line CW 320/14
2. E-Bike: Small Plate-Pasting Line
GLOBAL LEAD ACID CONSUMPTION IN BATTERIES 7
Source: CHR Metals Ltd. – Presentation at ELBC 2016
2015 BREAKDOWN OF CHINA’S LEAD USE IN BATTERIES 8
Source: CHR Metals Ltd. – Presentation at ELBC 2016
PRESENTATION OUTLINE 9
• Sovema Group S.p.A. Group Structure and Lead-Acid Product Offer
• Global Lead-Acid Consumption and Focus on Asian Markets:
• 2-Wheel Applications
• Sovema’s Strategy and Solutions for Small Plate Manufacturing:
1. Cast & Punch Grid Production Line CW 320/14
2. E-Bike: Small Plate-Pasting Line
10SOVEMA’S STRATEGY
SOVEMA’S STRATEGY:
• Sovema considers the e-bike/tricycle LA battery market very strategic for its
growth and has been heavily investing in it.
• Sovema can now advance state-of-the-art solutions for the manufacturing
process of the very small plates used in this market.
KEY DRIVERS OF SOVEMA’S STRATEGY:
• Top technology for best quality products
• Strong Business Case for lead savings
• Full Process Automation
• Reduction of Environmental Pollution
11SOVEMA’S PRODUCT SOLUTIONS
One solution for plate making specific for 2-wheel applications
12SOVEMA’S PRODUCT SOLUTIONS
What normally the Market offers to produce Punched Grid?
STRIP
CASTING
GRID
MAKING
CAST & PUNCH GRID PRODUCTION LINE CW 320/14 13
CONTINUOUS PROCESS
from the lead ingots to the punched grids
Lead strip
flow
Scrap return
flow
CAST & PUNCH GRID PRODUCTION LINE CW 320/14 14
SOVEMA’S SOLUTION:
• Combining two consolidated pieces of equipment into a single machine:
• Sovema’s Wide Strip Caster
• Sovema’s PunchPlus
• No lubricant needed in the punching process
• Continuous strip flow (no Stop&Go, no material stress)
IN-LINE GRID PUNCHING SYSTEM
CAST & PUNCH GRID PRODUCTION LINE CW 320/14 15
16CAST & PUNCH GRID PRODUCTION LINE CW 320/14
17
98 mm98 mm
Throughput: 1,500 Punched Grids/min
11 33 44
CAST & PUNCH GRID PRODUCTION LINE CW 320/14
An Example: 6 Punched Grids-Layout
Indicative grid measure
• Height: ≈ 72 mm
• Length: ≈ 49 mm
22
18
114 mm114 mm
11 33
Throughput: 2,000 Punched Grids/min
44
CAST & PUNCH GRID PRODUCTION LINE CW 320/14
An Example: 8 Punched Grids-Layout
Indicative grid measure
• Height: ≈ 55 mm
• Length: ≈ 57 mm
22
20
� Inlet Lead Strip Thickness Range: 0.7÷1.5 mm
� Grid Thickness Range with deformation: 0.7÷2.6 mm
EXAMPLES:
� 6 Punched Grids-Layout Throughput: up to 24.5 m/min Punched Grids
� 8 Punched Grids-Layout Throughput: up to 28.5 m/min Punched Grids
CAST & PUNCH GRID PRODUCTION LINE CW 320/14
PERFORMANCE:
21CAST & PUNCH GRID PRODUCTION LINE CW 320/14
KEY ADVANTAGES:
� Continuous flow of scrap returns from punching � optimization of
new alloy batch preparation
� Continuous process flow � no stress on the grid
� Production of rolled strips with a reduction ratio of 90% - 95% � high
corrosion resistance
MORE EFFICIENCY and LEAD SAVINGS
� Compact footprint
� Combined “CAST & PUNCH” � WIP reduction
� Clean scarp return (no oil) � less dross production
22E-BIKE: SMALL PLATE-PASTING LINE
SOVEMA SOLUTION
23E-BIKE: SMALL PLATE-PASTING LINE
DRUM PASTER, DIVIDER and DRYER
24E-BIKE: SMALL PLATE-PASTING LINE
DRUM PASTER, DIVIDER and DRYER
25E-BIKE: SMALL PLATE-PASTING LINE
DIVIDERDRYER
26E-BIKE: SMALL PLATE-PASTING LINE
PLATE CUTTER
AND STACKER
PLATE CUTTER
AND STACKER
E-BIKE: SMALL PLATE-PASTING LINE30
PERFORMANCE:
� Plate Thickness Range: 0.8÷2.8 mm
� 250 cut/minutes of grid strip
� Process speed can be as high as 750 plates/min
(6 Punched Grids-Layout)
� Process speed can be as high as 1,000 plates/min
(8 Punched Grids-Layout)
E-BIKE: SMALL PLATE-PASTING LINE31
KEY ADVANTAGES:
� HIGH PRODUCTIVITY AND EFFICIENCY
� RELIABILITY AND CONSISTENCY OF THE PROCESS AND PRODUCT
� REDUCTION OF ENVIRONMENTAL POLLUTION:
• Automation of all operations, from grid making to plate stacking
before curing
• Reduction of dust particle pollution thanks to plate cutting in
wet conditions
� REDUCTION OF MANUAL LABOUR:
• Plates are handled in strings with dimensions large enough to
allow process automation in all production phases
32SOVEMA’S STRATEGY
• Top technology for best quality products
• Strong Business Case for lead savings
• Full Process Automation
• Reduction of Environmental Pollution