When Web Handling Becomes a Multi-Million Dollar Problem - and How MapleSim Is Solving It

Jelly roll winding is where battery manufacturing's most expensive materials meet its most demanding precision requirements. At a 10-gigawatt facility, web handling failures at this single process stage cost an estimated $49 million annually during new product introduction. The root causes (interacting tension, alignment, roller, and speed dynamics) are well understood. What has been missing is a practical method for resolving them that doesn't depend on costly physical experimentation on live production equipment.

MapleSim for Web Converting Systems is that method: a physics-based, system-level simulation platform that enables battery manufacturers and machine builders to model, predict, and optimize winding dynamics before hardware is adjusted or material is consumed.