1. Tension Gradient Design
Winding tension must balance material stress and structural integrity. For example:
Initial tension: Set to 300gf for separators and 500gf for electrodes to stabilize material feed.
Tension decay: Reduce tension by 510gf per winding cycle to offset stress accumulation. This gradient prevents electrode fractures while maintaining layer adhesion.
Adaptive control: Real-time tension adjustments compensate for material elasticity variations, ensuring uniform winding density.

2. Temperature and Humidity Control
Moisture absorption and thermal instability can degrade separator performance. Critical standards include:
Dew point ≤40°C: Prevents separator moisture retention, avoiding uneven electrolyte wetting.
Humidity tolerance: Maintain relative humidity below 15% in the winding environment.
Thermal regulation: Heat separators to 25–30°C to enhance flexibility and reduce brittleness during high-speed winding.

3. Dynamic Radius Compensation
As layers accumulate, the winding radius expands, requiring precise speed adjustments. Key solutions:
Mandrel precision: Limit diameter errors to ±0.02mm to minimize concentricity deviations.
Archimedean spiral model: Calculate real-time radius changes to optimize winding speed.
Speed synchronization: Adjust linear velocity proportionally to radius growth, preventing slippage or layer misalignment.