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Present day battery production happens almost exclusively in large production lines where each machine is responsible for one step in the process chain. This results in low cycle time and low production costs per unit, but also in a largely inflexible production. With an increasing number of different applications and electric vehicle models, requirements for the battery systems and each battery cell varies in size and materials used. To test and judge the performance of a novel battery cell type before going into production, research and performance tests on ready-to-use batteries are inevitable. Prototypes are usually assembled manually at high costs, with no possibility to scale up their production and with typically low reproducibility. To handle this problem, a „Smart Battery Maker“ (SBM) pilot equipment, which produces battery cells with varying dimensions and materials, is being developed. The goals of the SBM are the proof of concept of fully automated prototype machinery that executes various production steps with a high reproducibility and the adaption of cell production steps to agile manufacturing. Different-sized pouch-cells are to be manufactured by the SBM equipment in small batches under industrial production conditions with minimal change of tools or equipment. To achieve this goal, the partners, namely KIT (wbk, TVT-TFT, IAM-ESS) and Fraunhofer ICT, will agree on different electrode and separator materials as well as different cell formats to be processed. The processability and reproducibility of overall production processes with the considered materials and cell formats have to be checked and verified. A prototype coating equipment for agile electrode production will be designed and built, as well as a compact robot cell that handles the production steps of single-sheet stacking, contacting and pre-sealing. To prevent any unwanted interactions with water, a dry room atmosphere and microenvironments will be considered for cell assembly. Electrode and separator sheets will be delivered to the SBM robot cell by a novel material transportation system that guarantees a protective microenvironment throughout transportation. Potential safety risks will be identified and quantified to ensure lawful operation. Quality assurance regarding reproducibility, safety and overall battery cell quality will be implemented. This includes a Failure Mode and Effects Analysis of all considered processes. Furthermore, the battery cells produced by the SBM will be tested on electro-thermal stability and will be compared to commercially available Lithium-Ion battery cells (e.g. by EUCAR Hazard Levels). By validating the SBM pilot equipment, the partners prepare the ground for a possible adoption of this agile concept by the battery cell industry. Production scale-up is easily manageable by using multiple robot cells, flexibility is given by the possibility to quickly adapt each equipment to different cell dimensions and materials.

Despite the wide range of applications and requirements, standardized cells are used for a lot of products. Standardized cells can’t fit all the different needs of the various battery driven products. Our hypothesis states that product manufacturers will demand batteries adapted to their requirements for electric properties and installation space. This will result in a growing variety of battery cells regarding dimensions, format and materials. This trend is already visible in batteries for consumer electronics like smartwatches and smartphones. To keep up with varying customer requirements, cell manufacturers will need suitable, flexible machinery to avoid large reconfiguration costs for every new type of cell. As a solution, an agile type of cell production equipment will be developed at KIT. Inspired by modern combustion engine manufacturing, the production system will consist of redundant robot cells of different types. Every type of robot cell will be responsible for a defined set of production steps and will be equipped with easily exchangeable production modules accordingly. Thus, the robot cell consists of the robot as a central handling, various production modules that execute the production processes and a microenvironment casing that ensures optimal climatic conditions for each production step. The production modules will be designed to use kinematic, tool-independent processes if possible and quick tool change if necessary to ensure flexibility. By adding or removing robot cells, the production system is scalable in ramp-up and ramp-down of products. Since a wide range of cells can be manufactured by the flexible equipment, the investment costs can be recovered over multiple product lifecycles. As a first step towards agile production, wbk is in the process of developing and building a robot cell for battery cell assembly that covers the production steps stacking, contacting and sealing. It will feature a microenvironment and a robot for handling the cell (stack). Being part of the ongoing project “SmartBatteryMaker”, two material systems (NMC622/ graphite and LFP/ graphite) and two different cell formats (rectangular and trapezoidal) will be able to be processed in the robot cell without the change of tools. To achieve “plug & work” properties in the production modules, a service-oriented machine control will be adopted. After giving a detailed description of the agile production in general, the presentation will give an overview of a planned project to adapt the concept of agile manufacturing to battery production. Furthermore, concepts and the state of the “SmartBatteryMaker” production cell will be presented. “SmartBatteryMaker” is the first step at KIT and wbk towards a flexible, agile production of battery cells.

Despite the wide range of applications and requirements, standardized cells are used for a lot of products. Standardized cells can’t fit all the different needs of the various battery driven products. Our hypothesis states that product manufacturers will demand batteries adapted to their requirements for electric properties and installation space. This will result in a growing variety of battery cells regarding dimensions, format and materials. This trend is already visible in batteries for consumer elec- tronics like smartwatches and smartphones. To keep up with varying customer requirements, cell manufacturers will need suitable, flexible machinery to avoid large reconfiguration costs for every new type of cell. As a solution, an agile type of cell production equipment will be developed at KIT. In a first step towards agile production, wbk is in the process of developing and building a robot cell for pouch cell assembly that covers the production steps stacking, contacting and sealing. It will feature a production modules to carry out the before mentioned processes, a simulated micro- environment and a robot for handling the cell (stack). Being part of the ongoing project “SmartBatteryMaker”, two material systems (NMC622/ graphite and LFP/ graphite) and two different cell formats (rectangular and trapezoidal) will be able to be processed in the robot cell without the change of tools. To achieve “plug & work” properties in the production modules, a service-oriented machine control will be adopted. After giving a detailed description of the “SmartBatteryMaker” equipment and processes, a first evaluation regarding produc- tivity, process capabilities and quality will be given. Finally, the novel production equipment will be rated via comparison with state of the art production lines to show potential improvements to be made in future adaptations of the agile production concept for battery cell manufacturing.

Trotz der Vielzahl von verschiedensten Anwendungen und Anforderungen an die Batteriezellen werden für viele Produkte standardisierte Zellen eingesetzt. Dabei werden individuelle Anforderungen, insbesondere an den Bauraum, meist nicht beachtet. Unsere Hypothese ist, dass künftige Produkte, vor allem in den Bereichen Unterhaltungselektronik, Power Tools und Elektrofahrzeuge, Batteriezellen benötigen, deren Anforderungen bezüglich elektrischer Eigenschaften und Format angepasst sind. Dies führt zu einer wachsenden Vielfalt an Batteriezellen in Bezug auf Abmessungen, Format und Materialien. Dieser Trend ist bereits bei Batteriezellen für die Unterhaltungselektronik wie Smartwatches und Smartphones erkennbar. Um den unterschiedlichen Kundenanforderungen gerecht zu werden, benötigen die Zellhersteller geeignete flexible Produktionsmaschinen, um hohe Rüstkosten zu vermeiden. Als Lösung wird am KIT eine flexible, automatisierte Produktionsanlage für die Li-Ionen Pouch-Zellen Fertigung entwickelt.