Innovative series production that is flexible in terms of the variety of components or fluctuations in the number of items and includes cost-efficient options for expanding capacity is the basis for establishing electric vehicles on the market.

As an experienced automation expert in the e-mobility sector, AKE technologies has developed innovative processes for the automated production of battery modules. In our technical news series "Module Assembly" we present the production steps in more detail, address the challenges and give an insight into our solution approaches.

PART 1 | Preparation processes for the assembly of battery systems with prismatic cells

In order to ensure smooth assembly processes, various preparatory processes must first be carried out on battery cells and side plates. During the preparation of the individual battery cells, the documentation and 100 percent traceability of the individual parts and all process data is ensured by DMC scan. An incoming goods inspection with OCV (Open Circuit Voltage), IR (Internal Resistance) and cell temperature test guarantees the processing of technically perfect cells with high quality. In the first process step of battery assembly, insulation foils are often attached to the side surfaces of the prismatic cells, which serve to avoid electrical flashovers between the individual cells. By cleaning the cell side surfaces beforehand with plasma treatment, a dust-free and grease-free surface can be guaranteed. The films are attached automatically. Depending on the cell arrangement and the component design, the insulation foils must be attached to different sides. These are glued with the help of handling or robot systems and so-called liners are removed. This is followed by the preparation of the side and end plates for assembly. The surfaces are - depending on the material used and on the required degree of cleaning - cleaned by means of plasma treatment or laser. A film application is then necessary here as well.

A major challenge in this process sequence is the component variance and the required variant management in the case of non-sorted operation. With the right control and buffer systems, we ensure correct pre-assembly of the respective component including provision of the required material at the right time at the correct station. Flexible grippers and innovative transport systems with a high degree of adaptability make it easier to implement the variety of options. A separation into parallel stations for different processing steps is possible without any problems, loops and switches can be built in to integrate additionally required process sequences.

In order to be able to implement the demanding processes in the required short cycle times, delta picker systems are used for component handling. Axis systems process the workpieces "on the fly". Camera tests and 3D scans are carried out in parallel with the machining process. In this way, we achieve cycle times in the region of around one second for particular sub-processes.

Further parts from the series "Module assembly"

• Module assembly - PART 2 | Stacking & Welding: High demands on process safety and quality
• Module assembly - PART 3 | From the pre-assembly process to the integration into the battery module
• Module assembly - PART 4 | End of Line Testing Guarantees Flawless Processing in Battery Module Production