Initial Situation
Several precisely coordinated process steps are required to assemble individual battery cells into a Battery Cell Stack. The cells are processed and positioned, while separator films and spacers are integrated into the assembly. At the European battery pack manufacturer, several of these steps were previously carried out separately. By introducing automation, the manufacturer aimed to combine these intermediate steps, improve process efficiency and ensure quality directly during production.
Requirements
The system had to reliably combine different assembly and inspection steps into one automated process. These included the precise handling and positioning of battery cells, the processing of insulation protection films and spacers, and quality inspection directly within the production process.
Solution by _ae
We developed an automated assembly system that integrates all process steps required to build Battery Cell Stacks into one complete system. The B&R SuperTrak transport system ensures material flow within the machine, while industrial robots handle and position the battery cells with precision. Integrated machine vision inspects defined quality characteristics directly during the ongoing production process. We designed the interaction between the individual systems as a fully integrated solution: mechanical and electrical engineering, software, robotics and machine vision work together seamlessly. We were also responsible for installation and commissioning at the customer's site.
Results & Benefits
Automated assembly combines several previously separate operations into one system, creating an efficient, continuous production process. The European battery pack manufacturer can produce Battery Cell Stacks in less time while benefiting from high repeatability. Integrated electrical and optical inspections ensure quality directly during processing. The result: higher productivity, reproducible processes and consistently high quality.
Facts & Figures
- Customer: European Battery Pack Manufacturer
- Industry: Battery Industry
- Markets: Electromobility / Rail Systems / Power Systems
- Application: Automated Assembly of Battery Cell Stacks
- Services by _ae: Mechanical and Electrical Engineering, Software Development, Robotics Integration, Vision Inspection, Installation and Commissioning
- Technologies: B&R SuperTrak Transport System, Industrial Robotics, COGNEX Vision Systems
