qualification and work environment
Why is the production of pouch cells so challenging? In a short interview, Simon Otte from the wbk Institute of Manufacturing Engineering of the KIT, explains which technological innovations are currently shaping the battery cell production – from continuous mixing processes to laser technologies. Find out how these developments increase efficiency and flexibility and what challenges must be mastered in the process.
The production of pouch cells is a highly complex and multifaceted task, that poses various challenges in terms of production, process optimisation and the introduction of new technologies. There are currently several promising innovations in the automated production of pouch cells, that have the potential to significantly improve efficiency, precision and flexibility.
The most exiting developments include continuous production technologies, such as continuous mixing to produce the slurry, and in-line digital process control with real-time quality monitoring. These innovations significantly improve efficiency and precision, but also pose new challenges, such as highly integrated sensor technology or digital twins for process optimisation.
Advances in laser technology for separating electrode sheets and handling sensitive electrode materials also enable more precise and faster stacking. The flexibility of this process increases the ability to adapt to new cell formats. Continuous stacking processes provide high accuracy and minimise the risk of damage, which contributes significantly to the quality of the battery cells. Concepts such as the Karlsruhe Institute of Technology´s “Exinos” system aim to achieve continuous process control through to the finished cell stack with the greatest possible format flexibility.
Scalability and automation are the focus of all these innovations to fulfil the requirements of modern battery cell production.
Integrating new innovations into existing production infrastructures and adapting production processes where necessary is a major challenge. This includes the implementation of inline quality assurance, the complete traceability of materials and intermediates throughout the production process, and the handling of large amounts of data for optimised process control. The combination of new cell materials with established processes is also technically challenging.
Digital twins are a key element in virtually testing and optimising production processes before they are implemented. The enable accurate modelling, early identification of sources of error and more efficient process control. The challenge is to accurately map the physical processes and integrate the relevant data.
The unit provides an in-depth understanding of the core processes involved in the production of pouch cellulose and gives an insight into current technology trends. Participants will learn how innovative technologies can be used efficiently to overcome challenges and to make production processes fit for the future.