Test & measurement
meant the new battery line could run for much longer periods without stoppages for re-greasing or component replacement, directly improving uptime.
Rollon equipped the TH series with effective sealing elements that safeguard the internal raceways from dust or particulate ingress. Thanks to this robust contamination control, the TH actuators are compatible with clean or dry-room environments required for battery production.
TIGHT SPACES AND HIGH SPEEDS: A COMPACT SOLUTION FOR AUTOMATION Space efficiency was a critical factor for the instrumentation and automation engineers designing the EV battery cell line. The production system consisted of many sequential process stations, each requiring at least one actuator for pick-and-place or positioning tasks. Fitting over 100 actuators into the line meant every millimeter of machine footprint mattered. The compact design of the TH actuators proved essential.
Despite their small size, the TH actuators did not compromise on performance or stability. Their high rigidity meant they could be mounted cantilevered or in tight assemblies without bending or deflection that would affect accuracy. Moreover, the lightweight construction reduced the load on the supporting framework, which is beneficial when an array of actuators are mounted on a larger moving gantry or when weight could cause vibrations.
The result was an automation solution that met the space constraints and high-speed requirements simultaneously – a combination often difficult to achieve. The OEM was able to arrange multiple actuators side by side for parallel operations, and stack different motion axes in a compact multi-axis configuration as needed, all while maintaining the stringent precision demands.
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INTEGRATING PRECISION MOTION WITH SENSOR-DRIVEN QA Modern EV battery manufacturing lines are heavily instrumented with sensors and vision systems to ensure each cell meets quality specifications. In this case study, several process steps included sensor-driven quality assurance. Such QA systems can only be as effective as the mechanical motion that presents parts to them. The Rollon TH actuators’ combination of high repeatability and stability provided a solid foundation for these sensor integrations.
Because each actuator could position a battery component or tool within a few microns of the target every cycle, the attached sensors were able to take reliable, consistent measurements. With the TH units, this was achievable even at full production speed – the actuators moved into position quickly and settled without oscillation, ensuring the thickness laser scan was not blurred by motion. Similarly, during the measurement of battery elements and final insertion of cells into their housings, the actuators’ precision meant that each component was placed within the exact tolerances the vision system expected. This level of repeatability under high dynamics is crucial: it prevents false rejects (caused by mispositioning rather than a real defect) and maintains tight quality control without slowing down the line. Essentially, the instrumentation (sensors, cameras, gauges) and the motion system worked in harmony, with the actuators ensuring the correct positioning and the sensors verifying the product quality in real time.
By automating the positioning for inspection and assembly tasks, the OEM’s solution eliminated much of the manual adjustment or slower pneumatic mechanisms that might have been used otherwise.
100+ ACTUATORS DRIVING A HIGH- SPEED PRODUCTION LINE
The collaboration between the OEM integrator and Rollon ultimately led to a comprehensive retrofit of the battery cell production line. In total, more than 100 TH series actuators were deployed at the facility, across multiple assembly and inspection stations. These actuators performed a variety of high-speed pick-and-place and positioning roles. Despite the range of tasks, all the actuators shared the same core requirements for precision and cleanliness, which the TH series met consistently. The new system proved capable of maintaining throughput while drastically reducing downtime related to lubrication or mechanical failures. In addition, the improved positional accuracy and repeatability provided a platform for the manufacturer to implement stricter in-line quality checks.
The success of the initial deployment led the manufacturer to extend the use of Rollon’s actuators to additional production lines. For the broader industry, this deployment demonstrates how choosing the right linear actuator can overcome common automation challenges in manufacturing.
Lee Cheshire, technical sales engineer at Rollon, explains: “Battery cell production places huge demands on precision and cleanliness, especially when lines run at high speeds with minimal tolerances. Our TH Precision System actuators are designed to deliver repeatable, micrometre-level positioning while maintaining a clean operating environment – key to supporting sensor-driven quality checks and consistent yield in manufacturing.”
Rollon
www.rollon.com/gbr/en/ September 2025 Instrumentation Monthly
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