Thickness Measurement Sensor

The Thickness Measurement Sensor is a precision component designed for integration into battery electrode calendering machines. Its primary function is to continuously monitor the thickness of electrode materials, including anodes and cathodes, as they pass through the calendering rollers. By providing real-time feedback on thickness uniformity, the sensor enables consistent electrode density and quality, which are critical for battery performance and safety.

The sensor typically employs non-contact measurement technologies such as laser triangulation, eddy current, or capacitive sensing. These methods detect the distance between the sensor and the electrode surface, and thickness is calculated based on reference points and calibration data. This approach avoids physical contact, reducing wear and preventing damage to the delicate electrode materials.

Key specifications include a measuring range of 0–100 μm, a resolution of 0.1 μm, and an accuracy of ±0.5 μm. The measurement speed ranges from 10 to 100 kHz, suitable for high-speed calendering lines. The sensor operates within a temperature range of 0–50 °C and requires a 24 V DC supply (±10%). It provides a 4–20 mA analog output for integration with PLC systems. The protection class is IP65 (IEC 60529), ensuring dust-tightness and protection against water jets. The sensor housing is made of corrosion-resistant stainless steel (316L, ASTM A240), and the weight varies from 0.5 to 2 kg depending on configuration.

When selecting or verifying this sensor, it is essential to confirm model-specific values and standards with the legal manufacturer or supplier. The listed parameters serve as reference ranges and must be validated for the intended application. The sensor is a component, not a standalone system, and its performance depends on proper installation, calibration, and integration with the calendering machine's control system.

The sensor operates on non-contact measurement principles, commonly using laser triangulation, eddy current, or capacitive sensing. In laser triangulation, a laser beam is projected onto the electrode surface, and the reflected light is captured by a detector. The angle of the reflected light changes with surface distance, allowing thickness calculation. Eddy current sensors generate a high-frequency magnetic field; changes in the field caused by the electrode material are measured to determine thickness. Capacitive sensors measure changes in capacitance between the sensor and the material, which vary with distance. The sensor continuously sends data to the control system, enabling real-time adjustments to the calendering process.