Tesla Texas Gigafactory · Beckhoff (TwinCAT / TwinSAFE)
Tesla Gigafactory — Electrode Slitting
What?
Uptime, quality, and safety improvements on the electrode slitting equipment (unwinding, slitting, and rewinding) within the Cell Manufacturing group at the Texas Gigafactory.
How?
Development on the Beckhoff TwinCAT / TwinSAFE platform using Structured Text and Function Block Diagram: S-curve motion profile for the slitters' speed controller; blade-unit tracking with RFID and a database; risk reassessment and safety-logic updates per Tesla standards; splice detection to prevent upstream quality defects using Keyence vision cameras; and a multi-tension controller for a segmented friction shaft using load-cell feedback on the rewinder.
Results
Reduced downtime, prevention of upstream quality defects, and compliance with Tesla's safety standards on the electrode slitters.
Confidential work: no public video available. The main sub-projects are presented as engineering highlights.