New energy battery intelligent manufacturing factory: case study of making miniature sand table models
1、 Project Background and Objectives
With the acceleration of global energy transition, the new energy battery industry has become a core pillar. A well-known battery manufacturer plans to participate in an international industrial expo, hoping to create a high-precision, dynamic demonstration sandbox model to visually showcase its latest intelligent battery production line to customers, investors, and the public.
Project Objective:
Intuitive display: Concentrate the complex battery production process (from electrode fabrication to chemical detection) into a square inch, making it easy for the audience to see at a glance.
Highlight technological strength: Through highly simulated equipment and dynamic processes, showcase the company's leading advantages in automation, digitization, and intelligence.
Enhance interactive experience: Utilize lighting, dynamic models, and touch screen controls to create an engaging visiting experience and become the focus of the booth.
2、 Design and Planning Stage
1. Content planning:
The team worked closely with engineers from "Chuangneng Technology" to determine the core demonstration process of the sandbox - the manufacturing process of lithium-ion battery cells. We have selected the five most representative sections:
Electrode preparation section: display slurry mixing, coating, rolling, and cutting.
Cell assembly section: display stacking/winding, shell insertion, welding.
Injection and sealing section: showcasing precise injection and laser sealing.
Chemical and testing section: Display the initial charging and discharging of batteries and quality screening.
Intelligent logistics system: Display the material transfer of AGV cars between production lines.
2. Sand table layout:
The sand table was ultimately designed as a miniature model with a scale of 1:25, measuring 2.4 meters x 1.2 meters. Adopting a "U" - shaped layout to simulate the assembly line design of a real factory, ensuring smooth visibility for visitors. The background wall is designed as a huge brand wall in corporate VI color, and embedded with a touch control screen.
3. Technical solution:
Structure: The main body is constructed with high-strength lightweight wood and acrylic panels to ensure lightness and stability.
Dynamic system: Simulate equipment operation and material flow using micro stepper motors, conveyor belt models, and LED light strips.
Control system: Using a central PLC (programmable logic controller) module, it receives touch screen instructions and coordinates the start stop, sequence, and rhythm of all motors and lights in a unified manner.
Audiovisual effects: Equipped with a small sound system, playing background music and commentary during presentations. Install micro LED lights on each key equipment node, indicating the status with different colors (such as blue for operation, green for completion, and red for alarm).
3、 Production and implementation phase
1. Basic scene construction:
Firstly, make a sand table base and lay grey adhesive that simulates industrial flooring. Use laser cutting to cut the pillars and beams of the factory building, and assemble the factory building frame. The walls and floors are treated with aging to increase realism.
2. Core equipment production (essence of model production):
This is the most challenging step, requiring extremely high precision.
Coating machine: Use acrylic rods with different diameters to simulate rollers, and wrap the surface with special stickers to simulate a metallic texture. Create a miniature material trough below.
Winding machine: Use extremely fine copper wire and insulating material to make miniature electrode sheets, and wind them around a core to display the initial form of the battery cell.
AGV car: 3D printed car shell, embedded with miniature magnetic coupling wheels and receivers, allowing it to automatically travel along a preset magnetic track path.
Robot arm: Purchase ready-made micro industrial robot models, modify them, and connect them to motors to achieve simple grasping and rotating actions.
All devices are hand-painted and aged to highlight the texture of industrial equipment.
3. Dynamic system integration and programming:
Connect the motor, LED strip and PLC controller. Programming is key, it is necessary to make the entire production process look coherent and reasonable:
Start: The audience clicks the "Start" button on the touch screen.
Process demonstration: The light in the electrode section lights up, and the coating machine roller begins to slowly rotate; After completion, the robots in the assembly section will start and pick up the components of the simulated battery cells; At the same time, an AGV car drove out of the warehouse to transport materials; The indicator light of the injection station flashes... the whole process repeats itself.
Commentary synchronization: When each section is activated, the audio will play a brief introduction of that section.
4、 Final Results and Effects
After six weeks, the sand table model was successfully completed. At the expo, it became a well deserved star exhibit.
Strong visual impact: The highly restored factory environment, precision operated micro devices, and dazzling lighting system create a miniature world full of futuristic technology.
Clear narrative: The audience can intuitively understand the complex process of battery manufacturing within 3 minutes, which cannot be compared to paper materials or videos.
High interactivity: Touch screen control gives the audience dominance, enhances participation and memory points.
