The fast-growing e-mobility market places high demands on battery cell production in terms of speed and efficiency. This is why intelligent, high-performance automation solutions are so essential. Our control technology enables end-to-end automation of all processes in battery manufacturing: from electrode production to module and pack assembly. PC-based control offers advantages for all machine types, no matter whether you produce round, pouch, or prismatic battery cells.
Your head start in battery manufacturing with Beckhoff:
- high speed thanks to fast cycle times
- optimal synchronization of control functions on a single platform
- execution of sophisticated motion tasks with up to 255 axes
- flexible scalability of hardware and software
Control technology for all battery production processes
High-precision battery cell winding
The rolling process used in round cell production involves winding a jelly roll from an anode strip, a cathode strip, and two separator strips. This calls for exceptional precision and speed.
Our control technology involves the use of a central PC-based automation platform to achieve maximum process efficiency in battery cell winding, as this allows vision systems, motion tasks, and communication to I/Os to all be controlled with a high level of synchronicity. It also enables not only precise winding accuracy, but also high output at the same time.
Our product highlights for the winding process:
- Vision portfolio: Image processing synchronizable with all control processes
- TwinCAT Motion Control: Modular software solution for sophisticated motion profiles – e.g., rapid and accurate synchronization of continuous to clocked processes
- decentralized drive technology: Servomotors with integrated servo drive
- EtherCAT high-speed fieldbus with exact timestamp function
Quick and accurate stacking of battery cells
Pouch cells are produced in a stacking process: Electrode sheets of cathode or anode material are placed between separator layers, for example with a Z-fold. Similar to the winding process for round cells, a high level of accuracy and speed are crucial in Z-folding.
With our modular TwinCAT automation software, even highly sophisticated motion tasks in the stacking process of battery cells can be executed with real precision. This makes it possible to control up to 255 axes synchronously. On the hardware side, a large portfolio of drive technology is available in various performance classes.
Our product highlights for the stacking process:
- TwinCAT Motion Control: Synchronous control of up to 255 axes, along with the integration of robot kinematics with NCI and robot libraries
- Compact drive technology: Motion solutions for operation in even the smallest of installation spaces
- XPlanar: Floating planar motor system for the transport or stacking process
Ensure safe electrolyte filling with components for explosion protection
Once the wound or stacked battery cells have been placed in their packaging, they are filled with the electrolyte. In addition to precise metering of the electrolyte liquid, adequate safety measures with regard to explosion protection play a major role in this process step.
We also offer integrated automation solutions for hazardous areas: Process technology requirements can be implemented directly via the central control platform and integrated into real-time applications. An extended product range is available for use in potentially hazardous areas.
Our product highlights for electrolyte filling:
- ELX terminals: Direct connection of intrinsically safe field devices from zone 0/20
- CPX series: Elegant control panels and panel PCs for use in zone 2/22
- Embedded PCs and bus couplers: System control and communication in zone 2/22
Flexible solutions for battery cell transport
For the initial charging and discharging processes and further cell aging, the battery cells are transported to various shelf storage systems after the electrolyte filling process. This primarily relies on roller conveyors and AGVs.
When it comes to controlling motor-driven roller conveyor systems, we offer a compact and seamlessly integrated solution in the form of the EP7402 EtherCAT Box. What’s more, our XTS and XPlanar intelligent transport systems allow you to completely rethink existing transport processes and design them with total flexibility.
Our product highlights for battery cell transport:
- EP7402 EtherCAT Box: Compact controller for motor-driven roller conveyor systems
- XTS with NCT: Enables handling and quality control during transport
- XPlanar: Floating product transport with maximum flexibility
Powerful robotics solutions for battery module and pack assembly
Batteries used in electric cars are first assembled into modules after production and then into larger packs. During module assembly, the individual battery cells have to be glued and welded together within a very short time. This is where precise robotics solutions are required for accurate and fast positioning.
TwinCAT enables the control of all common robot kinematics with modular software libraries. Direct integration into the central control platform ensures maximum performance and efficiency.
Our product highlights for battery module assembly:
- TwinCAT Kinematic Transformation: Integrates all common robot kinematics into the TwinCAT control platform
- Highly dynamic servomotors for gantries or delta pickers
- One Cable Technology: Reduces installation and cabling costs when connecting servomotors
- ATRO: Modular industrial robot system with standardized interfaces
Implemented worldwide: Beckhoff in battery manufacturing and e-mobility
Automation for highly precise and efficient production of lithium-ion battery modules
The rapidly growing electromobility market calls for particularly efficient manufacturing processes when it comes to the production of lithium-ion battery systems. This is where the BLS 500 laser welding system from Manz makes for an ideal solution, as it allows individual battery cells to be precisely contacted and connected to form battery modules. A high level of efficiency is ensured by means of a graphical programming tool and a virtual commissioning tool from Manz, as well as rapid PC-based control technology from Beckhoff and the continuous OPC UA communication this facilitates.
Linear transport system eliminates slow pick-and-place process
Low-cost lithium-ion battery cells (LIB) are the key to mass electromobility, although the manufacturing process has always been a cost driver – until now. Researchers at TU Berlin are using continuous Z-folding to replace the traditional pick-and-place movements that have been used so far, thereby accelerating battery cell production. The XTS linear transport system from Beckhoff has played a crucial role here.
Reliable and efficient operation due to fast and powerful control technology
Chinese automaker NIO aims to provide high-quality smart electric vehicles combined with an optimal user experience. The NIO Power energy service system makes a valuable contribution in this regard, using PC-based control from Beckhoff to ensure safe and efficient operation of NIO’s second-generation battery swap stations.
Further information
Automotive industry
PC-based control from Beckhoff supports modern manufacturing concepts for the mobility of the future.
Handling and assembly technology
PC-based control from Beckhoff optimizes the entire process chain: from preparation to production and assembly to testing and handling.