A New Concept for Small Plate Manufacturing Process · 2017-10-06 · PRESENTATION OUTLINE 2 •...

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


• Sovema Group S.p.A. Structure and Lead-Acid Product Offer






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


• Sovema Group S.p.A. Group Structure and Lead-Acid Product Offer






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


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

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


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


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


DRUM PASTER, DIVIDER and DRYER


DIVIDERDRYER


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

33

For additional information

visit us at our booths 68 & 69

[email protected]

A New Concept for Small Plate Manufacturing Process · 2017-10-06 · PRESENTATION OUTLINE 2 •...

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