1. High-Precision Tab Alignment
Accurate tab positioning is vital for minimizing internal resistance and weld defects. Advanced techniques include:
Laser die-cutting: Achieves burr-free edges (≤5μm) on tabs, reducing short-circuit risks during high-frequency vibrations.
Closed-loop alignment correction: Maintains tab spacing tolerance within ±0.3mm using real-time vision systems. This precision lowers virtual welding risks by 40%, ensuring reliable electrical connectivity.
Multi-layer stacking control: Aligns anode/cathode layers with <0.1° angular deviation for uniform current distribution.

2. Thermal Bonding Technology
Heat-induced layer slippage is a major failure mode in vibrating environments. Solutions include:
Patterned anode surfaces: Embossed textures (applied at 0.3MPa pressure) increase interlayer friction by 55%, reducing cyclic expansion by 20% .
Low-melt polymer coatings: Applied to separator edges, these coatings activate at 80°C, forming localized bonds that lock layers during thermal shocks.
Post-winding compression: A 5-ton press applies uniform pressure to enhance interfacial adhesion before cell aging.

3. Gradient Tension Control
Tension mismatches during winding cause internal stress buildup. Key strategies:
Tapered tension profiles: Starting at 180gf, tension decreases by 25gf per winding cycle to balance radial and axial forces.
Dynamic radius compensation: Adjusts winding speed based on real-time radius calculations using Archimedean spiral models, preventing outer-layer slack.
Elastic modulus matching: Optimizes separator/electrode stiffness ratios (1:3) to absorb vibration energy without delamination.