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.

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.

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.

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.

● 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.

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.