ParAlign Service Helps EV Battery Manufacturer Correct Misalignment Across 200+ Rolls in 6 Days

To prepare two newly installed EV battery production lines for high-performance manufacturing, a leading battery manufacturer hired the Fluke Reliability ParAlign Roll Alignment Service to measure and validate the position of over 200 critical rolls.

Working to a precision better than ±0.05 mm/m, the service supported mechanical corrections carried out by a Fluke Reliability partner, so that both lines met strict tolerances ahead of production for a global automaker. The alignment project was completed in just 6 days.

Key Takeaways:

• End-to-end alignment support: ParAlign measurement services supported a full alignment effort carried out in coordination with a trusted Fluke Reliability partner.
• 6-day alignment turnaround: The ParAlign team completed measurement and adjustments in just a little less than week.
• ±0.10 mm/m tolerance achieved for critical rolls: Critical rolls across both anode and cathode systems were aligned to meet EV-grade precision standards — a tighter tolerance than other industries.

Background

A leading European EV battery manufacturer had recently installed two new production lines — one for anode coating and calendaring, and another for cathode and separator lamination. These systems were designed to produce high-quality electrode foil for use in advanced electric vehicle batteries made by a global automaker.

Each roll in these lines plays a critical role in achieving the tight tolerances required for energy density, cycle life, and cell safety. “With the end product destined for a global automaker known for its rigorous engineering standards, alignment precision was needed before the lines could begin production,” the ParAlign service technician for the appointment explains.

In roll-to-roll battery manufacturing, even slight misalignments can introduce defects such as:

• Uneven electrode coatings, leading to inconsistent current distribution and poor cell balancing
• Skewed or folded separators, increasing the risk of internal shorts
• Tab misplacement or tearing, compromising weld strength and long-term cell performance
• Internal cell shorts, resulting from misaligned layers during stacking or lamination

These issues often remain undetected until final testing or field use, making early-stage alignment verification essential.

The rollers in each section of the machine had been pre-aligned at the factory, but after installation, the different parts of the machine needed to be aligned with each other on site. To make sure the new lines were within tolerance before production, the ParAlign team performed fast, high-precision roll measurement and supported alignment to the manufacturer’s stringent specifications.

Challenges

Aligning more than 200+ rolls across two newly installed production lines presented both technical and operational complexity. The customer required tolerances as tight as +/- 0.10 mm/m — significantly more demanding than those typical in industries like paper or film, where 0,30 mm/m is often sufficient. Achieving this level of precision ruled out visual checks or manual adjustments alone.

Because each roll adjustment needed to be confirmed in real time, the measurement process had to be not only accurate, but also repeatable and fast enough to support multiple iterations — without holding up progress.

While the machines were structurally similar, they were located in separate areas of the plant and required independent alignment.

Implementation

With over 230 rolls spread across two newly installed production lines, the alignment scope was significant — particularly given the tight tolerance target of ±0.10 mm/m. Yet, using ParAlign’s inertial measurement system, Fluke Reliability technicians were able to scan every roll in under two hours, without the need for line-of-sight setups or disassembly.

Unlike optical tools, which require extensive setup and a clear visual path between components, ParAlign captures alignment data simply by sweeping the device across each roll’s surface. This enabled rapid movement from roll to roll — even across large, multi-section machines — with no cumulative error.

To anchor accuracy across each system, technicians selected a single reference roll per line, providing a consistent angular baseline throughout the scan. This approach ensured uniformity while minimizing the chance of alignment drift across distant rolls.

Following measurement, a Fluke Reliability partner carried out the mechanical corrections. ParAlign technicians remained on-site to verify each adjustment in real time — enabling fast, section-by-section progress.

Results

With ParAlign’s fast, repeatable measurements, the teams completed alignment across both EV battery production lines in just 6 days. They validated that every roll met the required ±0.10 mm/m tolerance (or 0,15 mm/m depending of the rolls), so that both systems were mechanically ready for high-precision battery manufacturing.

The ability to remeasure instantly after each correction allowed for efficient, section-by-section progress without delays or guesswork. It also saved the manufacturer time and resources, since in-house alignment support was not necessary.

Most importantly, the alignment effort helped prevent downstream quality issues that could have surfaced only after the lines were operational — when correction would be far more costly. With all measurements documented and both lines in spec, the facility was able to proceed confidently toward production for a globally recognized automaker.