Specialty roll-to-roll modeling software designed to inject innovation and efficiency into the production of lithium-ion battery cell materials.

As battery production scales to meet global demand, manufacturers face increasing pressure to optimize roll-to-roll processes used for producing and handling electrode materials and during cell assembly. These processes involve the continuous movement of thin materials (webs) such as metal foils and polymer films through complex machinery, where maintaining precise tension is critical to product quality and throughput.

This is where MapleSim’s web handling simulation becomes a transformative tool. It provides an environment to simulate roll-to-roll systems and covers some of the intricate aspects of such systems directly related to cylindrical battery winding and prismatic battery production. 

• Multi-roller buffer systems design to handle cyclic web speed differences between different converting web lines. Challenges included: resonance and tension variation, kinematics and control for the range of motion
• Simultaneous winding of anode, cathode, and two separators and the tension oscillations caused by the inherent out-of-roundness of the jelly roll
• Optimizing web lines and accommodating production demands by quickly comparing the effect of dancer parameters, load cell locations, and feedback gains
• Providing deep insight into the evolution of the tension in the separate line of a stacking process