Calenders
Before calendaring, the dried electrode foil is statically discharged. The electrode is also cleaned before and after the compacting process, which includes exhaust. Compacting with the upper and lower roller results in improved contacting of particles and higher volumetric energy density. The electrode roller is rolled up again at the end of calendaring and is transferred to the next process step.
| System availability | Performance | Quality | |
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| Measuring the foil diameter |  |
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| Condition monitoring on the motor | |
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| Roller pressure monitoring | |
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| Sag control | |
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| Web edge control | |
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Exchanging the Mother Roller without Interruption
The carrier foil is supplied to the processing sequence by means of a roller. If an empty roller is detected too late, the roller replacement cannot be prepared and must be made on short notice. This brings production to a stop. A constant, accurate measurement of the mother roller diameter prevents this interruption and increases system availability.
Ensuring system availability
Enhancing performance
Solution
Ultrasonic sensors from ifm provide contact-free detection regardless of the colour, transparency or surface qualities of the object. That makes them ideally suited for carrier foils that may be reflective. ifm photoelectric distance sensors are also exceptionally well suited for this application.
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Condition monitoring on the motor
Preventing a Failure of the Roller Motor on the Calender
A failure or faulty function of the roller motors can lead to loss of a margin and high costs. Rotating components like bearings may fail for various reasons including overload or friction. Prevent downtimes and increase system availability.
Ensuring system availability
Solution
Thanks to continuous vibration monitoring by means of a sensor system, the health status of a fan can be kept in view seamlessly. Maintenance can be condition-based and determined by actual needs, which lowers costs. Early detection by means of vibration diagnostics and channel speed monitoring on rolling bearings detects motor damage promptly. This makes it possible to prevent unplanned downtimes.
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Ensuring the Correct Roller Pressure in the Calendar
Maintaining the correct pressure and coolant flow to the calendar rollers prevents quality problems with mother rollers in the downstream process.
Enhancing performance
Quality assurance
Solution
ifm pressure and temperature sensors measure precise roller pressure and temperature to ensure production quality.
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Ensuring a Continuous Resupply of Material in the Calendar
To ensure a continuous resupply of material, a material reserve is created in the form of a forward moving loop. Monitoring of the sag ensures the material supply and leads to more efficient production. A minimum value is checked, while another check ensures that the loop is not touching the floor. The forward moving loop can thus also act as a buffer to cover small interruptions.
Ensuring system availability
Enhancing performance
Solution
Ultrasonic sensors from ifm are ideally suited for use with shiny surfaces and for shiny or reflective surfaces of any colour. The photoelectric distance sensors are also excellently well suited for this application.
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Guiding the Web Edges Optimally at the Calendar
An efficient compacting process requires precise control of the web edge so that the offset is as slight as possible, preferably with none at all. The web edge is continuously scanned optically for this purpose.
Enhancing performance
Quality assurance
Solution
To control the web edge, ifm offers optical object detection sensors and profile sensors. The O2D in combination with the matching software ensures especially precise measurements.
