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E-mobility

Assembly lines for battery modules

AKE technologies acts as a system partner for its customers in the assembly of e-mobility components .

We offer our customers expertise in the development and manufacturing of assembly systems for complete battery modules at various levels of automation, from prototype lines to fully automated series production. For module assembly, we provide our customers with in-depth consulting services regarding automation feasibility, manufacturing processes, safety concepts, and much more. We always incorporate your individual requirements and develop assembly systems with the highest overall equipment effectiveness (OEE) – enabling you to produce your products cost-effectively, reliably, and with maximum efficiency!

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Pre-series production line for assembling battery modules | Combination of manual and automatic processing stations


General
  • Combination of manual and, if required, automatic assembly and processing stations
  • Flexible design through intelligent processing modules
  • Integration of setup trolleys and interchangeable machining modules
  • Expansion and reduction of the number of modules when quantities change
  • Complete data acquisition and process monitoring

Processes
  • Automatic feeding and incoming goods inspection of individual cells and cell modules in various designs (cylindrical cells, prismatic cells, pouch cells, modules made of prismatic or pouch cells)
  • Plasma or laser cleaning of battery cells and pretreatment of application surfaces: plasma, flame treatment, laser, liquid, ...
  • Assembly of the cells with monitoring of joining force and distance
  • Application of adhesives and gap filler systems including process monitoring via camera and 3D scanning system
  • Laser welding of contacts with process monitoring
  • Performing high-voltage (HV) activities in special HV cells (interconnecting modules, HV testing, covering open contact points)
  • Leakage test of the fully assembled system (air, helium, possibly with subsequent filling with a cooling medium)
  • End-of-line tests: communication test, plausibility check, audio frequency test, module functionality test

Automated assembly system for the production of battery modules from prismatic cells


General

  • Processing multiple cell variants on one system

  • High demands on variant management

  • innovative transport systems for flexible plant design

  • Combination of numerous individual processes in the smallest space

  • Integrated accident and emergency concepts in all process steps

  • Process monitoring and data transfer to a higher-level production control system, ensuring 100% traceability


Processes
  • Beginning of line inspection to ensure the processing of high-quality components
  • Cleaning and preparation processes on the cells, side and end plates (laser or plasma treatment, film applications, camera inspections)
  • Stacking & Welding processes for battery assembly
  • Pre-assembly and integration of the cell contacting system
  • End of Line Testing (Insulation and breakdown tests, cell temperature, voltage values)
  • Component marking for traceability
  • Automatic component dispensing and packaging of modules

Assembly plant for the production of battery modules and pack assembly from cylindrical cells


General
  • Automated assembly processes incorporating manual processing steps
  • Pre-production of various module variants
  • Electrical intermediate tests
  • Flexible pre-assembly of the battery housings
  • Automated final assembly area for inserting the battery modules and carrying out the HV activities
  • Option for later integration of an automated transport system into manual pre-assembly
  • Complete data acquisition and process monitoring

Processes
  • Automatic feeding and processing of individual cells (cell scanning, testing, cleaning)
  • Assembly of individual cells into battery modules (joining, laser welding, intermediate electrical tests)
  • Semi-automated pre-assembly of battery housings and covers (combination of manual placement and automatic screwing stations)
  • Automatic insertion of the modules into the pre-assembled tubs
  • High-voltage wiring of the battery system
  • Lid installation and leak test
  • Electrical in-line and end-of-line testing
  • Manual component labeling and packaging

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+49 851 95584-0 info@ake-technologies.de

Adolf-Höllinger-Straße 3, D-94034 Passau-Patriching

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