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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 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 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 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
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
Bild Hr. Schroer
Wanne-Kuslan
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 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=200–400 mm
W=125–200 mm
H=150–220 mm
L=200–520 mm
W=175–220 mm
H=175–220 mm
12–70 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
Passing height reduced to
Finger spacing
290 mm
290 mm
60 mm
We Deliver – Multi-Station Finishing Lines
High Rate Discharge/
High Voltage Test Machine
PLT:
6 batteries/min
Max. discharge current ranges:
Voltage range:
HVT:
6 batteries/min
Test Voltage:
1000 A
2000 A
3000 A
6– 14 V
100 – 12.000 Veff.
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 10 – 100 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
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 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 pos sibility to define your own registration con ditions 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
Exhausting-System
Droplet Separator
50.000 m3 /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 m3 raw acid tank
Turn-Key Formation Plant
10
We Deliver – Facility & Infrastructure Solutions
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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
www.digatron.com
Aachen, GermanyTel: +49 241 168 090 Fax: +49 241 166 465
Shelton, (CT), USATel: +1 203 446 8000 Fax: +1 203 446 8015
Qingdao, China Tel: +86 532 8870 5292 Fax: +86 532 8870 5259