E-mobility

Assembly lines for cell contacting systems

AKE is a manufacturer of fully automated assembly lines for the production of cell contacting systems in e-mobility.

Cell contacting systems (CCS connecting the individual battery cells in electric vehicles . They differ in numerous characteristics. Depending on the vehicle design and the OEM's requirements, there are different cell arrangements according to the available space in the vehicle; parallel or series connection is possible. The cells are assembled into single or double modules and are suitable for use in hybrid vehicles (HEV/PHEV) as well as in purely electric vehicles (BEV) .

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Concept example assembly system for cell connectors

AKE's production facilities offer an intelligent production concept for handling a wide variety of component variants without changeovers . Scalable system designs allow for different cycle times. Complete data acquisition and process monitoring take place during production, 100% traceability .

The following is an excerpt of the processes that are integrated into our assembly lines for cell contacting systems:

Processes

1. Automatic feeding of various individual parts

busbars
Power taps
Temperature sensors
Housing and support parts

2. Component-dependent preparatory work on the busbars

Equipping taps and sensors
Assemble
Laser welding
Stick

3. Mounting the prepared busbars in housings or support structures

4. Ultrasonic welding and hot riveting

5. Depending on requirements, combination with manual assembly stations (e.g., for cable assembly) or with rework stations

6. EOL testing

HV penetration tests
Communication tests of the functional assemblies

7. Component identification as DMC and plain text

Labels
Laser marking

8. Automatic placement in customer packaging

Trays
pallets

Documentation scope

Batch numbers of the individual parts
Traceability of individual safety-relevant components such as high-voltage separating elements
Joining forces and paths
Adhesive application parameters
Laser welding parameters
Camera evaluations
2D and 3D measurement results
Test results from the electrical tests
General information about the component, such as part number, production time, product variants, etc.

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