48 to changing market demands. Here, a standardised and modular approach can be very effective, says ATS Industrial Automation’s Roland Spiess. “Standardising your machinery, processes and documentation to allow for quicker and more efficient scaling of new lines, as does being modular in terms of the line’s configuration (footprint), and designating spots on the line for embedding future cells and stations. Technologies like system twin can help you plan future production line operations and configurations,” he says. With flexible automation, different equipment can be easily reconfigured or retasked for new assemblies, with little or no changeover or downtime, he notes. This principle applies even in the earliest stages of manufacture, including electrode mixing. The process section of all Coperion’s ZSK series extruders are of modular design, consisting of several barrel segments in which the co-rotating screws operate, Bernert says. “Using this construction, a broad variety of recipes can be produced on one machine by configuring the barrel and screw elements individually,” he adds. Increasing standardisation in cell packaging and geometry gives automated systems the flexibility to process a wide variety of cells and components with minimal effort, Dürr’s Bruhn adds, while new grippers with adjustable grid sizes and endeffectors enable the processing of a wide variety of products with the same manipulator. Another flexibility enhancing development is the interconnection of production processes using AGVs, which eliminates fixed connections. Digitised manufacturing operations management (MOM) solutions, such as that offered by Dürr and iTAC, make process flows more transparent and easier to control, he adds. Production lines can be adapted for batteries of the same cell format, such as cylindrical cells with different diameters, but they need modifications to handle different cell formats, ATS Industrial Automation’s Kühnast notes. She adds that while some production requirements are similar across all cell types, such as high-precision laser welding, the specific requirements for each type vary. These requirements are tied to cell formats – cylindrical, prismatic and pouch – and whether they are handled as individual cells or in modules or packs. There are other factors such as electrical connection schemes and power output that also have an impact on automation, testing and benchmarking requirements. Scaling up A modular approach to the production line allows scalability to be incorporated directly into its design, Spiess says. Designating spots for future cells and stations to be added ensures they fit within the line’s existing footprint. Modern tool chains, such as continuous integration/continuous deployment and test-driven development, often better known from the IT world, can easily be used in PC-based automation, as seamless integration is possible and standard interfaces to databases are already included, Beckhoff’s Rottkord notes. “The result is a high-performance, scalable architecture that makes extension of the line and automation system easy.” Taking a long-term view at the preproduction stage can equip companies for future scalability, Melischko says. “Designing a standardised production line that is modular and flexible in its configuration [means] new CAPEX costs are planned for and readily absorbed. Understanding the right level of automation and identifying future opportunities for adding automation can increase throughput.” Dürr is involved in the early planning stages for gigafactories, Bruhn says. “We plan and simulate complete, end-to-end factories, balancing throughputs, yields and our customers’ production scaling requirements on a case-by-case basis.” Gigafactories for cell manufacturing are typically built and extended in steps of 15-20 GWh using largely standardised equipment in modular layouts, he says. “Focusing on overall system efficiency while considering potential strategic challenges or product changes is important for establishing feasible concepts for long-term use.” Battery manufacture at scale is a rapidly evolving discipline that must be prepared to accommodate profound changes in the product’s core technologies in the design of production facilities – a conundrum that will continue to challenge the industry. Insight | Battery production technology July/August 2024 | E-Mobility Engineering Software-controlled, the XTS XPlanar component transport system uses electromagnetic fields generated by floor tiles and floating movers to create highly flexible lines (Image courtesy of Beckhoff)
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