項(xiàng)目背景
隨著全球新能源行業(yè)的迅猛發(fā)展，鋰電池生產(chǎn)已成為實(shí)現(xiàn)全球零碳未來(lái)的關(guān)鍵一環(huán)。在生產(chǎn)過(guò)程中，安全至關(guān)重要，尤其是在模切和焊接等工藝中會(huì)產(chǎn)生大量易燃易爆的粉塵。如果這些粉塵得不到有效處理，將給整個(gè)車間帶來(lái)巨大的爆炸風(fēng)險(xiǎn)。
東莞匯樂(lè)技術(shù)股份有限公司（以下簡(jiǎn)稱“匯樂(lè)”）長(zhǎng)期致力于工業(yè)除塵防爆技術(shù)的開(kāi)發(fā)，作為一線鋰電池生產(chǎn)商的長(zhǎng)期合作伙伴，匯樂(lè)在鋰電池產(chǎn)線積累了豐富的經(jīng)驗(yàn)。迄今為止，匯樂(lè)已在全球范圍內(nèi)為混料、壓延、分切、模切、疊片、繞卷、母線焊接、激光打標(biāo)等電池生產(chǎn)工藝提供了超過(guò)4萬(wàn)套設(shè)備，其中包括中央集塵與防爆系統(tǒng)，以及針對(duì)鋰電工況定制化的集塵器和壓料機(jī)。
Project Background
As the global new energy industry rapidly develops, lithium battery production has become a key element in achieving a zero-carbon future. Safety is paramount in the production process, especially during cutting and welding operations, which generate large amounts of flammable and explosive dust. If not effectively managed, this dust poses a significant explosion risk to the entire workshop.
Villo has long been committed to developing industrial dust collection and explosion protection technology. As a long-term partner of leading lithium battery manufacturers, Villo has accumulated extensive experience in lithium battery production lines. To date, Villo has provided over 40,000 sets of equipment worldwide for processes including mixing, calendering, slitting, cutting, stacking, winding, busbar welding, and laser marking. These solutions include central dust collection and explosion-proof systems, as well as customized dust collectors and waste compactors.
項(xiàng)目需求
某大型歐洲電池廠希望改善其激光模切車間的廢料收集設(shè)備，以減少粉塵殘留，降低燃爆風(fēng)險(xiǎn)，同時(shí)便于處理廢料，節(jié)省人力成本。
1.原有設(shè)備對(duì)廢料壓縮不充分，廢料松散，難以處理；
2.原有廢料收集設(shè)備框體內(nèi)有比較多粉塵殘留，若處理不及時(shí)，會(huì)有較高安全風(fēng)險(xiǎn)；
3.需要更智能化、易于操作以及維護(hù)的設(shè)備，以降低勞動(dòng)強(qiáng)度以及減少生產(chǎn)停機(jī)清理時(shí)間；
4.設(shè)備需要具備權(quán)威機(jī)構(gòu)的CE (ATEX) 認(rèn)證以符合當(dāng)?shù)?歐盟) 規(guī)定。
Project Requirements
A large European battery manufacturer sought to improve its laser notching workshop's waste collection equipment to reduce dust residue, minimize explosion risks, and facilitate waste handling while reducing labor costs.
To comprehensively address the client's issues, Villo proactively responded, conducting multiple on-site visits and engaging in detailed discussions with on-site operators and workshop managers. Through repeated dialogue and exploration, the core needs of the client became clear:
1.Insufficient compression of waste by existing equipment, resulting in large and loose,? ?waste blocks, which are difficult to handle.?
2.The existing waste collection equipment tends to accumulate a significant amount of dust inside the frame, posing a high safe risk if not properly handled.
3.Complex equipment operation and prolong maintenance, leading to high labor costs and production downtime for cleaning.
4.The equipment must be certified with CE (ATEX) by an authoritative organization to comply with local (EU) regulations.
結(jié)合車間現(xiàn)場(chǎng)的實(shí)際情況和客戶的核心訴求，匯樂(lè)通過(guò)其專利高效壓料機(jī)，為客戶設(shè)計(jì)了一套高效廢料收集方案，旨在從根本上解決當(dāng)前面臨的問(wèn)題。
Solution
Based on the workshop's actual conditions and the client's core needs, Villo designed an efficient waste collection solution using its patented high-efficiency waste compactor, aimed at fundamentally solving the current problems.
匯樂(lè)的廢料壓縮機(jī)自帶風(fēng)機(jī)動(dòng)力源，專為廢料壓縮、收集和除塵而設(shè)計(jì)。廢料和粉塵進(jìn)入后被有效分離，廢料被高效收集并壓縮成便于處理的塊狀，粉塵經(jīng)過(guò)兩級(jí)過(guò)濾后可直接排入車間環(huán)境。
Villo's Waste Compactor, equipped with its own fanpower source, is specifically designed for waste collection, compression and dust removal. Upon entry, waste and dust are effectively separated. The waste is then efficiently collected and compressed into
manageable blocks, while the dust undergoes thorough primary and secondary stage filtration, making it suitable for direct discharge (recycled back) into the workshop environment.
通過(guò)高效壓縮電缸（高達(dá)1:50壓縮比），壓縮后廢料整體成塊，便于回收。
兩級(jí)過(guò)濾，排風(fēng)潔凈度可達(dá)千級(jí)（H13級(jí)以上濾芯），回風(fēng)可直接排入車間。
活動(dòng)結(jié)構(gòu)采用光柵傳感器監(jiān)控，保證操作人員安全；大風(fēng)量設(shè)計(jì)可最大限度地將粉塵收集到收集箱中，顯著減少框體內(nèi)的粉塵量，提供更高的使用安全性。
可以24小時(shí)工作，減少停機(jī)清理時(shí)間，提高生產(chǎn)率，同時(shí)配備專利設(shè)計(jì)的收料小車，大大提高廢料回收效率。
配備惰化噴粉器及無(wú)焰泄放等防爆設(shè)備，大大提高安全性。?
經(jīng)匯樂(lè)高效壓料機(jī)壓縮后的廢料塊，便于回收
●?Efficient Compression:
The high-efficiency compression cylinder (with a compression ratio of up to 1:50) compacts the waste into solid blocks, making it easier to recycle.
●?High-Efficiency Filtration:
Two-stage filtration system ensures exhaust cleanliness up to Class 1000 (H13-grade or higher filter), allowing the return air to be directly discharged into the workshop.
●?Safety Protection:
The movable structure is monitored by a grating sensor to ensure operator safety. The high air volume design maximizes dust collection into the collection box, significantly reducing dust levels inside the frame and providing higher operational safety.
●?Continuous Operation and Convenient Recycling:
Capable of 24-hour operation, reducing downtime for cleaning and increasing productivity. Equipped with a patented collection cart design, it greatly improves waste recycling efficiency.
●?Explosion-Proof Option:
Equipped with explosion-proof devices such as an inert powder sprayer and flameless venting, significantly enhancing safety.
參數(shù)對(duì)比：匯樂(lè)壓料機(jī) vs 市場(chǎng)上某品牌壓料機(jī)
Comparison: Villo Waste Compactor vs. Another Market Brand
匯樂(lè)的高效壓料機(jī)通過(guò)優(yōu)化廢料管理，顯著提升了產(chǎn)線的效率和安全性。系統(tǒng)采用專利電缸壓縮技術(shù)，能夠高效收集并壓縮產(chǎn)線上的切割廢料，同時(shí)配備收集小車，讓廢料收集更便利，加上智能化控制實(shí)現(xiàn)與主生產(chǎn)設(shè)備的聯(lián)動(dòng)，確保生產(chǎn)過(guò)程自動(dòng)化運(yùn)行，大大減少人工操作成本。同時(shí)，壓料機(jī)可以24小時(shí)連續(xù)工作，減少了停機(jī)清理的時(shí)間，有效提高了生產(chǎn)效率。此外，大風(fēng)量設(shè)計(jì)最大限度地收集灰塵，顯著降低框體內(nèi)的粉塵量，提高使用安全性。實(shí)際投產(chǎn)后，該系統(tǒng)展現(xiàn)出卓越性能，解決了客戶在廢料管理上的難題，充分滿足了客戶對(duì)高效、安全生產(chǎn)的需求。
Villo's high-efficiency waste compactor significantly enhances production line efficiency and safety by optimizing waste management. The system uses patented electric cylinder compression technology to efficiently collect and compress cutting waste from the production line. It is also equipped with a collection trolley for more convenient waste collection. The intelligent control system integrates seamlessly with the main production equipment, ensuring automated operation and greatly reducing labor costs. Additionally, the compactor can operate continuously for 24 hours, minimizing downtime for cleaning and effectively improving productivity. The high airflow design maximizes dust collection, significantly reducing dust levels inside the unit and enhancing operational safety.?
After being put into operation, the system has demonstrated outstanding performance, effectively solving customers' waste management challenges and fully meeting their needs for efficient and safe production.
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