Increased flexibility and efficiency in battery production
Innovative development concept for a series-production system for stack formation
(PresseBox) ( Ditzingen ,February 19, 2025)
The development and industrialization of a new type of production plant for the manufacture of battery cell stacks is the goal of the EXINOS2 joint project (FKZ: 03XP0645A-F). The plant concept, which builds on the results of previous research projects, promises significantly improved efficiency and flexibility in battery cell production through the use of innovative technologies. In the joint project, researchers from the wbk Institute for Production Technology at the Karlsruhe Institute of Technology (KIT), the Fraunhofer FFB Battery Cell Research Production Facility and the industrial partners acp systems AG, BST GmbH, J. Schmalz GmbH and Siemens AG are working on the further development of the prototype plant concept. The Federal Ministry of Education and Research (BMBF) is funding the project with 3.64 million euros .
To produce battery cell stacks, the individual electrode sheets, each separated by a separator, must be precisely stacked on top of one another. In previous plant concepts, this is usually implemented using several automated gripping processes and rigid tools. There are inevitable breaks between the gripping processes, which lead to a discontinuous process. At the same time, the format-specific tools make it difficult to switch to other battery cell formats. If a new battery format is to be produced, costly new tools and time-consuming conversion work are necessary.
The system concept, which has already been built as a prototype, offers optimization potential with regard to both of these challenges. By creating a composite of the separator and the electrode sheets before the actual stacking process, a continuous and therefore overall faster process control can be achieved. The system technology itself is designed to be format-flexible, so that new cell formats can be switched to within a short time using software. This is achieved primarily by the flexibly adjustable handling systems, which are also used to cut the individual electrode sheets.
The efficiency and flexibility of battery production in Germany, which is expected to make a decisive contribution to the energy transition in the future, can thus be significantly improved. This in turn opens up great opportunities to strengthen economic power and technological innovation and to promote the expansion of electromobility.
Within the three-year project, all sub-processes of the prototype system concept are to be further developed and tested to ensure series production suitability in accordance with industrial standards. In addition, alternative technologies will be integrated and tested within the system. Digital methods play an important role here. For example, a multi-physical system simulation can help to optimize the position of individual components within the machine. In addition, the developed “digital twin” can accelerate the commissioning of the system and also provide valuable information for the machine operator within the production process. This can also build on previous research results from the battery competence clusters ProZell and InZePro, which are also funded by the BMBF.
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