CASE STUDY
Optimizing Lithium
Production for Electric
Vehicles Using OAV Air Bearings
OAV Air Bearings were used in the production of lithium metal tension control, improving efficiency, a smooth surface finish, and component life in EV manufacturing.
CUSTOMER
Company (NDA)
INDUSTRY
Electronic Vehicles
APPLICATION
Lithium Metal Control
PRODUCT USED
Air Bushings
BENEFIT
Process Stability
THE CHALLENGE
Lithium-ion batteries are essential to the performance, range, and reliability of electric vehicles. During lithium metal processing, maintaining precise and consistent material tension is a must in order to achieve uniform production quality. Any small variations caused by friction or mechanical resistance can affect material handling, leading to inconsistencies in thickness, surface defects, and material waste.
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For this application, the customer needed a motion solution capable of providing smooth, repeatable tension control while operating within a clean room environment. Conventional bearing systems lead to friction, wear, and mechanical variation in the process, which made precise tension control more difficult as operating conditions change.
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The customer looked for a motion system that would minimize mechanical contact and maintain stable motion throughout the lithium processing operation. Reducing friction was especially important for improving the process consistency while also limiting component wear and contamination concerns that conventional mechanical bearing surfaces caused.
THE SOLUTION
OAV Air Bushings were integrated into the lithium metal tension-control system to provide a frictionless surface between the stationary and moving components. The air bushings were machined into custom mounting blocks with pockets on both sides, allowing the bushings to be incorporated directly into the equipment.
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Rather than relying on rolling or sliding contact, the OAV Air Bushings operate on a thin film of pressurized air. This eliminates mechanical contact between the bearing and mating surface during operation, reducing friction and wear while providing smooth, repeatable motion.
Figure 1. OAV 0.500 inch Air Bushings were used to provide frictionless motion for precise tension control.
For lithium metal processing, this allowed the tension-control mechanism to respond without the mechanical resistance of conventional bearings. The non-contact operation made the technology well suited to the customer's clean room environment, where minimizing wear and particle generation is important to maintaining process conditions. Integrating OAV Air Bushings into the system allowed the customer to achieve the precise motion they needed for consistent lithium material handling while simplifying the mechanical interface responsible for tension control.
THE RESULTS
By using the OAV Air Bushings, the team was able to achieve significant improvements in their lithium battery production process.
Eliminated friction for precise and consistent tension
Improved surface quality and reduced material defects
Enhanced process stability in a clean room environment
Increased efficiency and reduced component wear
The OAV Air Bushings played a crucial role in enabling reliable, high-quality lithium production for the next-generation of electric vehicles.
SOURCE
Case study material based on information provided by Company (Non-Disclosed).