Intralogistik-Szenario Batterieproduktion: Im Spannungsfeld

Manufacturing industry is increasingly focusing on the production of storage cells — but the intralogistics scenario of battery production is highly demanding. SEW-Eurodrive and SYNAOS show how hardware and software work together to create solutions.

The lithium-ion battery is a superstar of the energy revolution.
Without them, there is no electric mobility suitable for everyday use. Without them, there is no traffic turnaround. Without them, there is no turning away from diesel and gasoline engines in cars, ships, airplanes, industrial plants or chainsaws.

Now it's up to superstars to keep the people around them busy with all sorts of idiosyncrasies, appeals and special requests.

The lithium-ion battery is no exception. At least when it comes to the way battery cells are produced.

The lithium-ion battery: A production diva

For example, powerful lithium-ion batteries for electric drives exist in a constantly dry, not too warm indoor climate. This is because their high energy content makes the materials extremely sensitive to dust particles, heat and humidity.

By way of comparison, while the humidity in the average German living room is between 40 and 60 percent, in battery factories it is around 0.04 percent at a constant room temperature of 20 degrees Celsius¹.

In addition, the components of a battery cell are extremely sensitive to shocks, shocks, vibrations and electrostatic discharge. Lithium-ion batteries, for example, contain flammable electrolyte, which can cause explosive fires in the event of falls or collisions. Electrostatic discharges can cause irreparable material damage.

Battery production: A growing market in an area of tension

Despite all the risk of explosion, battery production in Europe is a booming industry.

However, this is due to the fact that Europe is a laggard and not a pioneer. So far, Asian companies have dominated global battery production. Massive investments by the western automotive and mobility sector are intended to change just that.

In North America and Europe alone, 80 battery-producing gigafactories are currently planned — or already connected to the grid. Analysts from management consultancy McKinsey assume that 150 new giga factories will be needed worldwide by 2030 to meet global demand for electric mobility².

High standards of intralogistics

The production of battery cells is therefore extremely relevant, very complex and highly sensitive. As a result, the manufacturing industry and intralogistics face numerous challenges.

“In terms of intralogistics, battery production is just as demanding as the pharmaceutical industry, let's just think of cleanroom requirements. In addition, these industries place high demands on the digitization of manufacturing and the interplay of information processes,” explains Steffen Strickrodt, Vice President Customer Success at SYNAOS.

“Traditional production sites often resemble clean, tidy workshops. In comparison, we have to think of battery factories more like operating rooms: clinically pure, sterile, almost aseptic. Because the end products are highly complex,” continues Strickrodt, “the processes must be very precise, fast and smooth.

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Robots don't smoke or stumble

Battery factories have an intralogistics scenario that is particularly demanding for people. This makes the use of robots and driverless transport vehicles (AGVs) not only economically attractive in terms of efficiency, but also virtually indiscriminate in terms of susceptibility to errors and product safety. AGVs are indispensable helpers in battery production.

It may sound trite: But robots don't smoke, they don't inadvertently blow harmful particles into the air. Robots don't trip, freeze, break their backs when carrying 800 kg of cathode material.

“The carrying capacity, robustness and reliability of FTF makes them indispensable helpers in battery production. Our partners at SEW-Eurodrive have been working for years on how to build specialized AGVs for the requirements of intralogistics in battery production. We work together very successfully on major projects and are always impressed by the hardware that SEW-Eurodrive develops and markets,” says Strickrodt.

SEW-Eurodrive and SYNAOS: Specialized hardware, adaptive software

“Our AGVs, which were specially developed for battery production, have a stainless steel structure. They are intended for use in ISO 6 class cleanroom applications. For example, this enables controlled entry and exit processes between white and grey areas in battery production,” explains Daniel Geider, Industry Segment & Account Manager at SEW-Eurodrive.

He continues: “The way lithium-ion battery cells are manufactured is subject to constant change. Some process steps use highly innovative processes. That is precisely why every customer project is individual and sometimes requires new solutions. With the Movi-C modular automation kit and Maxolution system solutions, we can react flexibly to all battery cell production requirements and automate manufacturing processes as well as material handling and transportation. ”

Lionel Roche, MAXOLUTION® System Solutions — Mobile Assistance Systems Sales, adds: “The mobile assistance systems from SEW-Eurodrive can seamlessly connect various production areas of a battery factory and transfer loads of over 1,000 kg between vehicles with the required precision. At one of Europe's largest battery plants, we are using 42 driverless transport vehicles of various designs in the first expansion stage. The longest distance traveled is 345 meters, including an elevator ride. ”

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Sustainability through scalability

“The more complex the tasks become, the more important the interplay between hardware and software — and its scalability,” explains Steffen Strickrodt.

In a joint solution from SEW-Eurodrive and Norwegian machine manufacturer Tronrud Engineering, the SYNAOS Intralogistics Management Platform is used as a central control system. The software solution orchestrates intralogistics in a demanding production environment and directs the mobile robots via the standardized, interoperable VDA 5050 communication interface. “With regard to the configuration and nature of batteries, there have been no clear priorities or dominant standards so far. As a result, vehicle and battery manufacturers must be flexible. Intralogistics systems play a special role here, as they must enable flexible production,” explains Strickrodt.

“The profitable collaboration between SYNAOS and SEW-Eurodrive is an example of how hardware manufacturers and software providers must look for one thing in particular — the greatest benefit for their joint customers. ”

Lionel Roche from SEW-Eurodrive also sees it this way: “Battery production is an important growth market. And a major challenge that requires special solutions that can also be scaled in other applications. We are looking forward to working in partnership with SYNAOS on further projects as well.”