The call-off figures in the e-mobility sector are still relatively low compared to conventional vehicles. When now considering the production of E-components for premium vehicles, concepts for small batch production are of particular interest. To meet the requirements of OEM's and suppliers, AKE technologies GmbH has developed a concept that impresses with its high flexibility and efficiency in the production of small quantities. Battery cells of all designs are processed into modules and packs on the systems. Various pre-assemblies, for example of battery management systems, are also integrated.

Flexibility of the processing modules enables adaptation to call-off quantities and component variants

The concept for manufacturing battery systems with comparatively low call-off rates combines automatic and manual processing stations. The setup cart principle and intelligent processing modules with exchangeable component fixtures increase flexibility. Changes in the number of call-offs can also be accommodated by expanding or reducing the number of machining modules. The linking of the individual modules is implemented with manual transport carts by the worker, later automated guided vehicles can also be integrated.

Ensuring correct manual assembly through worker guidance and process control

A comprehensive worker guidance system supports and relieves the employees, ensures quality in production and a smooth assembly process. For example, guided, coordinate-monitored screwdriver systems are installed. Assembly activities are visualized on the operator panel or by projection lasers directly on the components. Pick-by-light systems ensure that the correct components are used, and plant software makes sure that the correct assembly sequence is maintained. The connection to the customer's MES (Manufacturing Execution System) documents the individual manual assembly steps and parameters for seamless traceability.

Worker protection during HV assembly activities

Most of the HV assembly processes are integrated into self-contained high-voltage cells. Manual assembly activities in the HV state of the battery - such as inserting the module packs into the pre-assembled housing and screwing the module packs or module connectors together - are implemented taking into account protective measures for the worker, such as special protective equipment.

End of line testing and integrated data management for quality assurance and traceability

Various end-of-line tests (optical, electrical and leak tests) ensure component quality. For example, communication tests, plausibility tests, HV and functional tests are integrated. Production data is transferred to a higher-level production control system for 100% traceability. In addition to individual part traceability of safety-relevant components, test results from 2D and 3D measurements, electrical and leak tests, and the parameters of laser welds and gapfiller applications are also stored.

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> Learn more about various concepts for assembling battery modules!