Automation for highly precise and efficient production of lithium-ion battery modules

Application-specific customizable laser platform

A prime example is the new Battery Laser System (BLS) 500, which is designed as a flexible platform for the various laser processes used in the manufacture of lithium-ion batteries. Starting from a standardized machine base, it can operate individually as a single system where the workpiece is loaded manually or as part of an integrated production line to achieve high-precision laser welding, as well as laser cutting and drilling, or partial material removal.

In the BLS 500 application described here, a battery module consisting of round battery cells is inserted into the machine manually in a laboratory scenario, but otherwise this is an automated process. The individual cells are then welded to the contacting elements by laser. As a graphical programming tool, the SmartLaser Assistant uses the CAD data of the underlying battery module to create the associated recipe, i.e., the optimum path calculation for all welding points as well as the appropriate laser power in each case. Stephan Lausterer, Head of Software Core Design and Product Development at Manz, describes the clear application advantage as follows: “Our programming tool makes it much easier to adapt the BLS 500 to diverse applications, i.e., to different cell types and module formats.” He adds that the result can then be conveniently examined in Manz’s virtual commissioning tool, and not only that: “Commissioning is accelerated and simplified by the fact that using the model the control program can be tested in detail and realistically in advance, i.e., before the machine has actually been mechanically assembled. In addition, high precision is achieved by using image processing to compare the CAD data of the battery pack with real-life data and to take any offset values into account during the welding process. In all these aspects, we benefit from the TwinCAT control software with its convenient and powerful OPC UA integration.”

System advantages of PC-based control

The importance of high-performance and, above all, flexible control technology has also increased significantly at Manz in recent years, and it was this that ultimately led to the partnership with Beckhoff which has been sustained for over ten years now. Stephan Lausterer explains this in more detail: “Originally, Manz developed its own control technology; however, this became increasingly difficult due to the growing relevance of electronics in mechanical engineering and the exceptionally fast innovation cycles in this field. We therefore went in search of a suitable specialist as a new control supplier. In a corresponding benchmark, PC-based control proved to be the optimal solution, in particular due to the PC-based concept and the flexible, open, and finely scalable system architecture. In addition, there was the innovative strength of Beckhoff – a factor that we regarded highly even back then.”