ABB has officially launched its new low-stress shape control system tailored for ultra-thin metal strip applications. Leveraging high-precision control and robust design, this revolutionary solution for cold rolling mills enhances metal processing efficiency and cleanliness across industries such as electronics, automotive, and aerospace.

Surging Demand for Ultra-Thin Metals Drives Technological Upgrades

Driven by the lightweighting of electronic devices, advancements in new energy vehicle (NEV) battery technologies, and the development of medical precision components, the market demand for aluminum foil, copper foil, and precision steel strips as thin as 5 microns continues to surge. However, conventional rolling processes face challenges in controlling shape, thickness consistency, and equipment stability, particularly in ultra-thin material production where noise interference and precision degradation often occur, leading to increased scrap rates and costs.

Innovative Technology Addresses Industry Pain Points

ABB’s new low-stress shape control system, built on Stressometer® sensor technology, redefines production processes through three core advantages:

1. Ultra-Precise Detection: Integrated into a compact measuring roll with a diameter of just 200mm, the system detects minute stress changes with gram-level precision, enabling precise control of shape, thickness, and tension for foil materials ranging from 50 to 5 microns. This is particularly critical for finishing processes of ultra-thin materials below 20 microns.
2. Robust Durability: The mechanical design significantly reduces maintenance requirements, with wear-free characteristics lowering life cycle costs. Simplified ancillary systems and reduced compressed air consumption further decrease energy consumption.
3. Intelligent Environmental Adaptation: Temperature compensation algorithms optimize measurement stability, ensuring high-resolution data output even under complex operating conditions, thereby sustaining continuous and efficient production line operation.

Marko Sydanlammi, Global Product Manager for Force Measurement at ABB’s Measurement & Analytics business unit, stated, “This system directly addresses customers’ core needs for quality, productivity, and energy efficiency. Even under the demanding conditions of foil production, it ensures long-term equipment stability, supporting enterprises in their low-carbon transition.”

Global Validation Accelerates Industry Adoption

The system has undergone pilot validation at South Korean electric vehicle (EV) battery manufacturers and specialty aluminum foil plants in Europe and Asia, demonstrating significant improvements in product qualification rates and reductions in rework costs. By expanding measurement capabilities to meet foil application demands, the new low-stress system enriches ABB’s product portfolio, advancing its mission to help industries achieve leaner, cleaner operations and set new benchmarks for excellence.

As ultra-thin metals gain traction in new energy, 5G communication, and biomedical sectors, ABB’s low-stress shape control system is poised to become a cornerstone of cold rolling process upgrades, driving global manufacturing toward greater efficiency and sustainability.