Digatron Formation Solutions Integrated Turnkey Engineering from one Source

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Egbert Brooks
6 years ago
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1 Digatron Formation Solutions Integrated Turnkey Engineering from one Source

Synergy through Turnkey Solutions Acknowledged Expertise you can trust Since 40 years Digatron is the world s premier designer, manufacturer and integrator of automated formation and test systems for

We are focussed for such a long time to the battery branch and have serviced successfully several hundreds of worldwide battery manufacturers sites, so it was a logical step to enhance our expertise

2 Synergy through Turnkey Solutions Acknowledged Expertise you can trust Since 40 years Digatron is the world s premier designer, manufacturer and integrator of automated formation and test systems for all the battery industry and its related sectors. We are focussed for such a long time to the battery branch and have serviced successfully several hundreds of worldwide battery manufacturers sites, so it was a logical step to enhance our expertise further in engineering and implementing complete formation systems and fully integrated turnkey projects that meet our clients expectations from the market leader. Project Management from one Source Managing professionally such turnkey projects require an in-depth knowledge and well proven project management. The key to the Digatron Project Management is the people that bring their expertise into the team. So beneath the demands on hardware like equipment and technology, the processes and the proven software solutions, the professionalism and experience of the team is the prerequisite for managing and putting such integrated systems into operation successfully. Linking Expectations with Success To meet with success your expectations, the Digatron Project Management Team integrate the solid knowledge base of experienced engineers, all coming out of the respective field itself, be it the battery industry, the material handling supplier or the industrial control systems. The project manager is the focal point for the customer and the project team. He drives and controls a reliable flow of information within the team and links it prompt and transparent towards the customer. This includes regular status reports, project flow charts and progress reports. The Digatron Project Team has successfully managed complete formation projects, starting from the floor plan for the formation plant, calculating electrical power, cooling water & air ventilation requirements as well as the rectifier layout. Efficiency through Synergy As the single contractor Digatron warrants more a rapid, a more flexible and therefore a more efficient integration of leading technology solutions. Our understanding is not only to use latest technology, but lasting technology in terms of high quality, best performance at minimized lifetime cost. And, last but not least, due to the synergy effects of an integrated package, this even offers unequaled competitiveness. Benefits of unique Systems Integration Utilizing our strong and experienced engineering team, we also provide the required systems and facility integration, e. g. for acid filling, water cooling tanks, ventilation & filtering, water treatment, materials handling and finishing line. Digatron s Project Management Team is your only responsible contact partner starting from the layout plan till commissioning, always ensuring planning and process reliability to meet your expectations for even greater performance.

We Deliver - Total Project Engineering Battery Filling Acid filling machine Acid supply infrastructure Formation System Automatic formation water bath Main electric panel & installation Hard- and

Finishing Line Leveling machine Acid supply infrastructure Automatic plug setting machine Washing & drying machine Production line & high voltage tester Post finishing machine Hot marking & labeling

3 We Deliver - Total Project Engineering Battery Filling Acid filling machine Acid supply infrastructure Formation System Automatic formation water bath Main electric panel & installation Hard- and software controls Formation Rectifier IGBT or SCR based charging circuits Temperature controlled formation Battery Manager host computer Rectifier room adaptation Air-condition for rectifier room Finishing Line Leveling machine Acid supply infrastructure Automatic plug setting machine Washing & drying machine Production line & high voltage tester Post finishing machine Hot marking & labeling machine Palettizing handling machine Cooling System Cooling tower or Chiller Cold & warm water infrastructure Exhausting System Droplet separator Exhausting infrastructure Exhausting and cooling frame Facility and Conveying Infrastructure Complete conveying infrastructure including rotation units, automatic loading & unloading conveying lines and shuttles Lead connection cables, wiring of power & data leads Valves, pumps, pipes and control systems Building adaptations like acid resistant floor coating Documentation Scope of supplies & part lists Commissioning instructions Manufacturing instructions Maintenance plan Measures to maintain battery performance Safety instructions

We Deliver - Customized Formation Modules Traditional Water Bath Formation Fully automatic water bath formation system Acid resistant stainless

Cooling water level gauge Control panel for drives and level control Fume hood with slide paneling Safety micro switches Automatic water

Schroer Wanne-Kuslan AGM Water Bath Fully automatic AGM water bath formation Acid resistant stainless steel construction Flexible no.

4 We Deliver - Customized Formation Modules Traditional Water Bath Formation Fully automatic water bath formation system Acid resistant stainless steel construction Single structure containers Pneumatically driven gates, self-locking and unlocking Built-in motor-driven roller conveyor Cooling water level gauge Control panel for drives and level control Fume hood with slide paneling Safety micro switches Automatic water temperature regulating system Compressed air system Bild Hr. Schroer Wanne-Kuslan AGM Water Bath Fully automatic AGM water bath formation Acid resistant stainless steel construction Flexible no. of rows, drop-off positions and containers Palette conveyor system X-Y Handling system Positioning control Cooling infrastructure Temperature controls Automatic transport system Automatic contacting system Host computer for Operation Parameterization Visualization

We Deliver - Customized Formation Modules Acid Recirculation Technology Fully automatic formation process Density control during

shortened formation times Savings through omission of Acid filling equipment Washing equipment Cooling equipment Waste water

Infrastructure Complete conveying infrastructure including rotation units, automatic loading & unloading conveying lines and

5 We Deliver - Customized Formation Modules Acid Recirculation Technology Fully automatic formation process Density control during formation Temperature controlled process Homogenous formation results Modular concept No disposal of aerosols Savings through shortened formation times Savings through omission of Acid filling equipment Washing equipment Cooling equipment Waste water treatment Additional exhaust system Reduced return on invest Reduced operating & maintenance cost Facility and Conveying Infrastructure Complete conveying infrastructure including rotation units, automatic loading & unloading conveying lines and shuttles Lead connection cables, wiring of power & data leads Valves, pumps, pipes and control systems Building adaptations like acid resistant floor coating

We Deliver Multi-Station Finishing Lines Filling/Leveling Machine Car & Truck Batteries L0-L2: L3-L5: MAC, A, B, C: Filling

Plug type: single plugs, screw type, valve type Battery size: Car batteries: Truck batteries 4-5 batteries/min Battery weight:

machine length: Total machine width: Total machine height: Wash zone temperature: Fresh water final rinse temp.

6 We Deliver Multi-Station Finishing Lines Filling/Leveling Machine Car & Truck Batteries L0-L2: L3-L5: MAC, A, B, C: Filling precision: Filling control: 6 batteries/min 4 batteries/min 2 batteries/min ±1% of volume by flow meter Plug Setting Machine Plug type: single plugs, screw type, valve type Battery size: Car batteries: Truck batteries 4-5 batteries/min Battery weight: L= mm W= mm H= mm L= mm W= mm H= mm kg Washing Machine 6 batteries/min Total machine length: Total machine width: Total machine height: Wash zone temperature: Fresh water final rinse temp.: 8600 mm 900 mm 2500 mm approx.60 C approx.85 C Transport system: 620 mm passing width reduced to 290 mm Passing height reduced to 290 mm Finger spacing 60 mm

We Deliver Multi-Station Finishing Lines High Rate Discharge/ High Voltage Test

discharge current ranges: Voltage range: 1000 A 2000 A 3000 A 6 14 V HVT: 6

Post-Finishing Machine Brushing Greasing Hot Marking 6 batteries/min Total

7 We Deliver Multi-Station Finishing Lines High Rate Discharge/ High Voltage Test Machine PLT: 6 batteries/min Max. discharge current ranges: Voltage range: 1000 A 2000 A 3000 A 6 14 V HVT: 6 batteries/min Test Voltage: V eff. Post-Finishing Machine Brushing Greasing Hot Marking 6 batteries/min Total machine length: Total machine width: Total machine height: 3800 mm 900 mm 2500 mm Labeling Machine 10 batteries/min. Wipe-on for adhesive Label mm paper passage incl. Release-Paper Continuous bypass Optical sampling Release-paper rewinding Automatic label positioning Max. label length 300mm Height and width adjustable

We Deliver State-of-the-Art Formation Rectifiers MCR/ MCDR The MCR/MCDR is designed for the wet container formation process and contains multiple charge/discharge circuits for various types of

The MCR/MCDR is available with different current ranges from 5 to 100 Ampere and could either be used for air-cooled or watercooled formation processes.

8 We Deliver State-of-the-Art Formation Rectifiers MCR/ MCDR The MCR/MCDR is designed for the wet container formation process and contains multiple charge/discharge circuits for various types of batteries. The number of batteries that could be charged per circuit depends on the maximum DC output voltage of the rectifier (e.g. a 360V circuit could charge 20 batteries in series). The MCR/MCDR is available with different current ranges from 5 to 100 Ampere and could either be used for air-cooled or watercooled formation processes. A unique safety and long term stability feature are the galvanically isolated charging/discharging circuits. They are equipped with a contactor disconnect and protected by a 3-phase AC breaker and two DC fuses. Construction The MCR/MCDR rectifier comes with a solid framework made of welded steel. Its rugged design allows forkliqft transportation without additional tools. The cabinets could either be installed side-by-side or back-to-back. The high circuit density per cabinet results in a smaller cabinet footprint and thus requires less floor space. Hinged front doors with safety interlocks ensure protection against accidental contact and allow access to the terminal strips. All covers are removable for ease of service. The cable entrance for input power and DC outputs provide access from the bottom with terminal strips. The location of the main input circuit breaker offers sufficient space to connect each rectifier cabinet to the main power supply. The protection mode is IP20. Forced cooling by a fan and guided air flow from bottom to top assure an optimum heat dissipation. The cabinet s standard painting is gray (RAL 7032) and has an acid resistant epoxy resin lacquer coating.

We Deliver Formation Software Solutions The All-In-One Software Solution The solid knowledge of a worldwide acting company with 40 years of experience with the demands of the battery industry has

Features and Benefits Battery Manager provides utmost formation process efficiency in establishing an integrated platform connecting all Digatron devices as well as linking external devices such as

It reduces in-process inventory using a unique software algorithm to optimize the utilization of formation process resources.

9 We Deliver Formation Software Solutions The All-In-One Software Solution The solid knowledge of a worldwide acting company with 40 years of experience with the demands of the battery industry has been incorporated into the Battery Manager - the battery testing and formation software solution indigenously developed by Digatron. Features and Benefits Battery Manager provides utmost formation process efficiency in establishing an integrated platform connecting all Digatron devices as well as linking external devices such as temperature chambers, water baths or other controls like density meters to one common database. It reduces in-process inventory using a unique software algorithm to optimize the utilization of formation process resources. It features an easy-to-use operating interface allowing to generate or display all relevant process steps of a battery formation procedure. Battery Manager is an inherently stable software for the Windows XP platform and provides network capabilities to control the formation lines and its circuits from any location of a plant. Passwords can be assigned to single users or groups for secure access control of vital program settings. All recorded data collected from the formation process is recorded in a Microsoft SQL server database. The data could be used easily to create a customized management and production report by using third-party software like Crystal Reports from Seagate. Program Editor Tool to create new formation programs as well as viewing, editing and deleting existing programs Handling similar to Windows Explorer Powerful features, such as visualization of a program s function in a diagram and the possibility to define your own registration conditions for every program step. Floor View Offers a graphical representation of the formation room installation Displays building infrastructure details like walls, doors, windows, etc. mapping the formation site

We Deliver Facility & Infrastructure Solutions

000 m 3 /h Water Cooling Tower: Thermal transfer

5 MW Input temperature 35 C Output temperature 25

measuring system Conductivity measuring system

10 We Deliver Facility & Infrastructure Solutions Exhausting-System Droplet Separator m 3 /h Water Cooling Tower: Thermal transfer capacity up to 1.5 MW Input temperature 35 C Output temperature 25 C Bypass capability at low ambient temperature ph measuring system Conductivity measuring system Sulfuric Acid Supplying Station: Tanktruck Fillingstation 100 m 3 raw acid tank Turn-Key Formation Plant 10

11 We Deliver Facility & Infrastructure Solutions 11

12 Digatron - We Deliver Total Project Management Key Features & Benefits Pre-engineering studies Customized product & process design Individual machine configuration in 3D CAD Customized adaptation of all process parameters Local installation support & commissioning at site Long term process stability and product quality Future-proof technology due to suitability for upgrades and extensions Reduction of downtimes through process stability Assistance for precautionary and corrective maintenance Optimized interfacing through central project coordination Trustworthy through worldwide reference projects Excellent performance reputation High level of cost transparency Flexible financing models Fast track projects! Digatron s Added Value Battery Solutions beyond Engineering Battery Design Types: Built & Specifications Container & lid design, plug & valve construction Grid design of pos. & neg. plate Specification of separators & glass mats Definition of cell package & inter-cell connections Specification of materials and key production parameters Manufacturing & process control instructions Aachen, Germany Tel: Fax: Shelton, (CT), USA Tel: Fax: Qingdao, China Tel: Fax:

There are two leading power conversion technologies used in formation charging rectifiers

There are two leading power conversion technologies used in formation charging rectifiers 1 2 3 A goal of any progressive battery manufacturer is to shorten formation time while reducing energy consumed during the process. The requirement to increase capacity while reducing operating expense