EL-THICKNESS: High-precision thickness measurement as a key factor in battery production
The battery industry is operating in an area of tension between increasing production volumes and, at the same time, the highest demands for quality, safety, and efficiency. Particularly in lithium-ion batteries, even the smallest deviations in material thickness directly affect the performance, energy density, and service life of the cells. Especially in electrode production, in addition to basis weight measurement in the coating lines, thickness measurement after the press rollers is of crucial importance for the functionality of the cells. Only the continuous measurement of material thickness after the press makes it possible to detect deviations and correct them accordingly. This ensures the required capacity as well as uniform material homogeneity and reduced porosity in subsequent processes.
The demand for ever higher line speeds while maintaining consistent quality places enormous requirements on measuring technology. Conventional measuring methods quickly reach their limits here, whether due to insufficient accuracy, inadequate stability, or complex integration into existing systems. What is required are solutions such as EL-THICKNESS that can measure precisely, without contact, and continuously without negatively influencing the production process.
As of July 2026
With EL-THICKNESS, Erhardt+Leimer offers a non-contact online thickness measurement system that meets the high demands of battery production in terms of precision, stability, and system integration. Chromatic-confocal sensors enable measurements with an accuracy better than 1 µm and detect even the smallest fluctuations in real time. This allows processes to be corrected immediately, reduces production waste, and ensures consistently high product quality.
A special feature of the system is the C-frame made of carbon fiber reinforced polymer (CFRP). It combines high stiffness, low weight, and minimal thermal expansion. This improves measurement stability, simplifies integration into existing production lines, and ensures reproducible measurement results even under demanding production conditions. Continuous data acquisition also supports Industry 4.0 strategies, data-driven process optimization, and more efficient resource utilization.
Precise measurement as the basis for stable processes
In battery production, thickness measurement is not an isolated step, but an integral part of process control. While the focus in coating lines is on basis weight, thickness measurement is of decisive importance particularly in the calendering process. Here, the coated material is compacted so that the final thickness and therefore the corresponding energy density of the cell are achieved. Automatic thickness measuring systems ensure accuracies in the micrometer range and make a significant contribution to process stability.
Continuous online measurement offers decisive advantages. Deviations are detected immediately, control loops can react in real time, and production waste is significantly reduced. Thus, transparency in the production process increases, which is of central importance in the context of Industry 4.0 concepts and data-driven optimization and serves as the basis for AI.
Non-contact online thickness measurement EL-THICKNESS for the highest demands
With EL-THICKNESS, Erhardt+Leimer offers a solution designed for the special requirements of battery production. The system enables continuous, non-contact measurement of material thickness and supports manufacturers in maintaining constant quality standards and controlling production processes efficiently.
At the core of the system is the use of state-of-the-art sensor technology. Chromatic-confocal sensors guarantee high-precision detection of material thickness and allow measurement accuracy down to the micrometer range. Even the smallest fluctuations can therefore be reliably detected and compensated. This is crucial particularly for sensitive electrode materials, where every deviation can have a direct impact on cell performance. An integrated MSA test to ensure measuring equipment capability is a fixed component of the system.
Stability and dynamics thanks to the C-frame made of CFRP
A key differentiating feature of the EL-THICKNESS system is the innovative C-frame made of carbon fiber reinforced polymer (CFRP). Compared with conventional granite frames, this design combines several decisive advantages that directly affect measurement quality and integration into production lines.
Thanks to its high stiffness combined with low weight, the carbon fiber frame offers exceptional stability, which can be further optimized through design modifications with a negligible increase in weight. This results in additional advantages compared to other materials. At the same time, the CFRP frame exhibits very low thermal expansion, meaning that measurement deviations can be disregarded even with minor temperature fluctuations. This ensures consistently reproducible measurement results – even under the most demanding production conditions.
The low weight of the CFRP frame significantly reduces installation effort, making integration into new or existing systems much easier. In addition, the slim design allows space-saving installation in often confined production environments.
Technological performance
The EL-THICKNESS system with C-frame made of CFRP impresses not only with its mechanical properties, but also with its metrological performance. Chromatic-confocal sensors enable measurement accuracy better than 1 µm.
The integration of currently common interfaces such as EtherNet/IP or Profinet, as well as support for established interfaces such as Profibus, ensures seamless integration into existing control and automation systems. This allows the system to fit perfectly into modern, networked production environments and supports the implementation of data-based optimization strategies.
Added value for battery production
For manufacturers in the battery industry, the use of the EL-THICKNESS system creates clear added value. High-precision, continuous thickness measurement enables a significant reduction in production waste and rework. At the same time, process stability is increased, which directly results in consistently high product quality.
The system also supports more efficient use of resources. Through exact compliance with material specifications and the resulting lower scrap rate, material consumption can be optimized. This is not only economically relevant but also contributes to a more sustainable production process.
Last but not least, continuous data acquisition creates the basis for further analyses and optimizations. In combination with higher-level systems, trends can be identified at an early stage, maintenance measures can be planned more effectively, and production processes can be improved in a targeted manner.
Conclusion
The requirements for battery production will continue to rise, both in terms of quality and efficiency. High-precision and reliable measuring systems are therefore a key factor for success. With the EL-THICKNESS system and the innovative C-frame made of CFRP in combination with the latest sensor technology, Erhardt+Leimer offers a future-proof solution that combines the highest measurement accuracy with robust design and easy integration.
Frequently Asked Questions (FAQs)
EL-THICKNESS is a non-contact thickness measurement system from Erhardt+Leimer for continuous online measurement in battery production. It supports consistent quality standards and efficient process control.
Out-of-tolerance deviations are detected immediately, control loops can react in real time, and production waste is reduced. At the same time, transparency throughout the production process is increased.
The system uses chromatic-confocal sensors that enable highly precise thickness measurements with an accuracy better than 1 µm.
The MSA test (Measurement System Analysis) ensures measuring equipment capability and helps guarantee the long-term reliability of measurement results.
The CFRP frame is lighter, highly rigid, and exhibits very low thermal expansion. This enables stable and reproducible measurement results even under temperature fluctuations. The lower frame weight also contributes to smoother system operation, which has a positive effect on measurement accuracy.
In addition, the reduced weight simplifies transport, installation, and integration into existing production lines.
EL-THICKNESS supports modern interfaces such as EtherNet/IP and Profinet, as well as established standards such as Profibus, allowing easy integration into existing automation environments.
Through continuous acquisition and provision of process data, trends can be identified, maintenance activities can be planned more effectively, and data-driven optimization strategies can be implemented.
The system is particularly suitable for thickness measurement after the calendering process. This is where the final electrode thickness is defined and where the future performance of the battery cell is significantly determined.