The Critical Role of Double Sheet Detection in EV Battery Manufacturing: A Comprehensive Guide to Preventing Fires and Machine Damage

Executive Summary

The global transition toward electrification has reshaped battery manufacturing. As electric-vehicle production scales, battery cell lines process thin electrode materials at high speed, and the tolerance for defects becomes tighter. In electrode manufacturing, one important anomaly is the inadvertent feeding of double electrode foils, which can create equipment risk, scrap, and downstream cell-quality concerns if it is not detected and controlled.

This guide explains the role played by Double Sheet Detection systems in the electrode manufacturing process. It examines mechanical and electrochemical risks associated with double feeds, the vulnerabilities of calendering and cell assembly equipment, and the importance of sensor technologies. Central to this discussion is ultrasonic sensing technology, specifically the MDC Double Sheet Detection Sensor provided by Yujie Piezo Technology, which helps distinguish between single, double, and spliced layers of micrometer-thin anode and cathode foils. By integrating these sensors, manufacturers can add a documented control point for equipment protection and electrode handling.

The analysis examines ultrasonic attenuation, separator mechanics, and the triboelectric behavior of electrode foils. It also explains why non-contact double-sheet detection can be a practical control point as the industry pushes toward higher energy densities and thinner current collectors. The MDC sensor is one option for teams that need documented detection behavior before calendering, stacking, or other sensitive process steps.