Your Partner for
Battery Manufacturing
siemens.com/battery © Siemens AG 2016
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Prospects for the battery market
3
•
Value added chain and process
10
•
Automation technology and
expertise
16
•
Linear integration and
connection to the control level
23
Barriers and challenges for the battery industry and machine building
Complex value chain
Economic challenge
Changing technology
Rapid growth
Shortage of crude oil Government Subsidies Urbanization
& Regulations
Climate change Lowering unit costs Pack transportation Consistent Quality Global markets
costs
Form factor Energy
density/weight Service life/ charging cycles Further development of cell chemistry Hybrid manufacturing process Machine integration Quality measurement Complex production
Energiepeicher für elektrische Antriebskonzepte in Fahrzeugen
Applications for large-format battery cells
Stationary energy stores for increased
system quality and for regulating
fluctuations in demand, especially in
the case of power from renewable
sources
Stationary storage
Automotive
Leisure vehicles
Mobile machines
Heavy industry
Electrodes Battery cells Battery packLithium Ion
Traction
Stationary storage
Technology leaders must predict the future
In d u s tr ia l d e v e lo p m e n t E c o n o m ic c h a ll e n g e s ChallengesReproducibility
Productivity
Pilot machine
Control of individual processes
200x
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Market
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Process
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Networks
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Measuring
technology
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Science &
research
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Export
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Transparency
of production
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Downtime
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Efficiency
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Time-to-market
Complex
production
Form factor +
cell chemistry
Quality
Machine
integration
Global markets
Scale effects
Electrochemical
developments
Individual machine
Interlinking, quality measurementInline machine
Horizontal integration, KPI (quality), SCADALinear solution
Horizontal/vertical integration, KPIs (quality, production), SCADA, MES
Next
generation
The global market potential for traction batteries will rise sharply until 2025
Global market for lithium-ion traction batteries
Regions
Drive segments
Global market 2025 [$ billions]
MHEV = Mild Hybrid Electric Vehicle SHEV = Strong Hybrid Electric Vehicle PHEV = Plug-in Hybrid Electric Vehicle REX = Range Extender
EV = Electric Vehicle
Source: A.T. Kearney (10/2012) Note:
Cells including cell materials, packs including cells, battery management system and cooling; split between regions and drive segments refers to packs
SHEV
MHEV
E-bike
EV
REX
PHEV
36%
7%
40%
11%
3%
3%
0
20
40
60
80
100
120
140
160
"Slow" scenario
"Moderate" scenario
Cell materials
Cells
Packs
Europe
Japan
China
Other
46%
21%
21%
5%
7%
NAFTA
Key segments in the market for stationary storage are energy generation
and "prosumers"
Quelle: SiemensOverall market 2020:
3.15 GW (€3.7 billion)
Li-Ion
Power generation
• Large plants, renewable energy
generation
• Conventional power plants
• Distributed generators
"Prosumers"
(refers to producers who are also
consumers)
Grid Storage
• Distribution
• Transmission
Others
Others
21%
57%
in GW
in GWh
Middle East, Africa
Asia / Pacific
GW
36%
33%
28%
2%
Americas
Europe
Global market for lithium-ion batteries for stationary storage systems 2020
Li-ion technology's share
of the overall market (2020)
Regional division (2020)
Market segmente
Battery costs are crucial in transforming a trend into the mainstream
750
1,000
1,250
1,500
1,750
2,000
0
250
500
2025
2030
2006
2010
2015
2020
281 $
Source: OEM and supplier interviews conducted in Asia, Europe and North America; McKinsey analysis
High
Average
Low
Scenario
~ 1,100 $
~ 720 $
~ 390 $
Fully automated and linked production lines are required to achieve the cost target.
•
Prospects for the battery market
3
•
Value added chain and process
10
•
Automation technology and
expertise
16
•
Linear integration and
connection to the control level
23
Value added chain for battery manufacturing
Material manufacturing
Electrode manufacturing
Cell manufacturing
Battery manufacturing
Battery integration
1
2
3
4
5
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Cell production
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Cell startup
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Assembly of battery
modules/packs
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Assembly and connection
technology
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Tempering
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Battery management
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Safety/performance tests
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Integration of the battery
packs into the EV
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Anode
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Cathode
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Foil
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Separator
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Anode material
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Cathode material
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Binder
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Carbon black
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Separators
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Electrolyte
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etc.
Machine builders
Description of the process
1. Electrode production
Battery cell manufacturing
* Drying and slitting/punching also shown in reverse sequence• Compression of the
electrode material to
minimize porosity
• Preventing the material
surface from bursting
• Material mix dried in oven
• Reduction in residual
humidity
• Cutting the length and
width of the foil with
high-precision
cutting/punching/laser tool
• Avoidance of material
particles on the surface
• Electrode material mix is
applied to the sur-face of
the metal foil. Slitter
ensures precise material
thickness;
• Anode: copper
• Cathode: aluminum
• Mix of the electrode
material Anode: carbon,
cathode: lithium metal
oxide with conductive
binder
• Homogenous distribution
of the components
required
Mixing
Coating
Compression
Drying*
Slitting/punching*
1
2
3
4
5
Cell assembly
Addition of electrolyte
Formation/aging
Test/categorization
Packaging
6
7
8
9
10
Description of the process
2. Cell assembly and testing
• Activation of the reaction
by means of
charging/discharging with
staged increase in voltage.
• Storage 2-4 weeks
• Categorization in Classes
A/B/C by measuring the
self-discharge, internal
resistance, and capacity of
the cell
• Sorting of the cells
according to categorization
• Transport conditions as
freight is hazar-dous (fire
hazard if cells damaged)
• Electrolyte is added in
clean room.
• Toxic reaction with
atmospheric humidity!
Sealing, cleaning
• The separator is placed
between electrodes.
• Connection of the
electrodes to poles and
safety components,
installation and sealing of
the case
R R
Description of the process
3. Battery module assembly
• Attachment of the battery management system (BMS) board
• Welding and cabling of the monitoring sensors (charge, voltage, temperature) • Testing of the sensors and
connections
• Precise positioning of the
cooling plates and screws
• Fitting of enclosure and
attachment of the cables
with cable grip
• Connection of test devices
• Pressure test (leak
tightness of cooling
system)
• Voltage test
• BMS test
• Selection and pick-up of
cells and precise
placement in prepared
module base
• Homogenous connection
of the cell conductors by
welding
• Checking of the welded
connection
Battery module mounting
Stacking
Contacting
Battery management
Cooling system
Quality test
1
2
3
4
5
Description of the process
4. Battery pack assembly
• Installing the current software on
the battery management system
• Checking of all systems
• Establishing even charging of the
cells
• Mounting the module cover and
pack cover including sealing strip
• Leakage test
• Mounting the rupture diaphragm
• Pick-up of battery modules and
insertion in battery pack
• Screwing to battery pack base
• Installing the cooling system
• Attaching the battery management
system
• Attaching the high-voltage module
• Cabling the connections and
securing the cable harness
bar Flashen
Battery pack assembly
Module assembly
Battery management
Charging/flashing
Final assembly/test
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Prospects for the battery market
3
•
Value added chain and process
10
•
Automation technology and
expertise
16
•
Linear integration and
connection to the control level
23
Application: electrode coating
• Flexible and fast control of the coating system with SIMATIC S7 for high-precision coating
• Easily parameterized standard applications for setpoint-cascade, winder with tension control, etc.
• Fewer rejects due to automatic roll change during operation with reversing winders or goods storage
• Controllers, drives and motors scalable for all requirements and power ratings • Simple and safe integration of quality measuring systems into the automation
solution on Profinet based on Standard Ethernet
Customer benefits
Flexible, double-sided, intermittent strip coating at up to 50 m/min:
• Homogenous coating thickness of 150-300 µm • Tolerance for coating of 1-2 µm
• Prevention of build-ups at the start and end of the coat • Integrated quality inspection of coating thickness, area mass,
and surface structure
• Optional integrated calendering of the electrode (inline) • Fast adaptation of the process in the case of quality flaws • Constantly high speed of the winder drives
• Automatic roll change
• Integration into plant network
Requirements
Machine
Automation solution
PROFINET PROFIsafe
SINAMICS DCC W inder
SINAMICS DCC Line Tension Control
e.g. 1FK7 motor series for material transport and winders
I/O: ET200 (F) SINAMICS S/G: Auxiliary drives (AC/AC)
SINAMICS DCC RGJ (ramp-function generator with jerk limiting) SINAMICS DCC Accumulator SINAMICS S120 SIMATIC S7 (F) Machine automation Standard applications Dryer
Reversing unwinder Reversing winder Coating
system II
Coating system I
Application: compression of the electrode material
• SINAMICS DCC: Free, parameterizable and tested standard applications for winders, speed synchronization, tension control and main drive
• Open source code for individual adaptations to the application
• High quality: precise and constant tension due to motors with low torque ripple for winders with low tension values at low speed
• High quality due to high-speed PROFINET communication
(250 µs) for high-dynamic and precise control of the hydraulic axes at high speed • Low wiring outlay due to standard/fail-safe application on one hardware system
Customer benefits
Calender at up to 50 m/min:
• No damage to the material
• Precise setting of the gap (+/- 1 µ)
• Automatic, high-precision gap adjustment • 300 tons of pressure at maximum speed
• Openness for simple integration of online quality measurement systems into the control system
• Fast engineering and commissioning in accordance with international guidelines and standards
Requirements
Machine
Automation solution
Rewinder Unwinder Calender (tension control) (tension control) PROFIsafe PROFIsafe SINAMICS DCC W inderSINAMICS DCC Line Tension Control SINAMICS DCC RGJ
e.g. SIMOTICS-S 1FK7 or SIMOTICS-H 1PH8 for material web drives and winders SINAMICS DCC W inder SIMATIC S7 (F) Machine automation Standard applications
Application: slitter & rewinder
Machine
• SINAMICS DCC: Free, parameterizable and tested standard applications for winders, tension control and main drive
• Open source code for individual adaptations to the application
• High control quality, precise web control, precise/constant web tension due to servomotors with low torque ripple even at low tension values and low speeds • Scalable solutions for automation and drives engineering, for uses ranging from
laboratory machines to industrial plants
• Flexible operation using fail-safe W-LAN Mobile Panel
Customer benefits
Slitting & winding at up to 150 m/min:
• Precise processing
• No damage to the material
• Web widths up to 1.2 m, unwinder up to 1 m, material 75 to 150 µ diameter • Automatic cutter adjustment
• Integration into plant network
• Integration of system for measuring the cutting edge
Requirements
Automation solution
PROFIsafe PROFINET PROFIsafe I/O: ET200 (F) SINAMICS S/G: W eb drives SINAMICS DCC W inderSINAMICS DCC Line Tension Control SINAMICS DCC RGJ SINAMICS DCC W inder SIMATIC S7 (F) Machine automation Standard applications e.g. SIMOTICS-S 1FK7 or SIMOTICS-H 1PH8 for material web drives and winders
Cutter & cutter positioning
Unwinder Winder I Winder II Pressure roller Pressure roller Tension control
Application: punching/slitting
Mechanical punching of prismatic electrodes from webs of material
Automation solution
Machine
• Easily parameterized standard applications for winders with tension control and punch
• High-precision slitting quality due to flexible, fast and high-dynamic synchronization of the slitting tools, and jitter-free closed-loop control and measuring probe functionality
• Drive concept tailored to requirements in each case
• Competent support from application specialists with technology expertise
Customer benefits
Punching of prismatic electrodes from material webs moving at up to 100 m/min:
• Flexible punch shapes, A4 format
• Sharp cutting edges without burrs/fraying • No damage to the coating
• Constantly high speed of the winder drives
• Max. accuracy in gear synchronism or in cam synchronism when punching • Optional detection and marking of flawed areas in the coating
• Integration into plant network
Requirements
Optional PROFIsafe PROFINET PROFIsafe SINAMICS DCC W inder SIMATIC S7 (F) Machine automation Standard applications Punch Winder + tension controlMark Detection
Application: assembly
Kinematics for assembling prismatic cell stacks
Automation solution
Machine
• Simple axis coordination and zone definition
• Predefined gantry kinematics and advance motion simulation in 3D-Trace • Optimal combination of traversing speed and positioning accuracy
• Simple parameterization with standard handling library • Simple integration of drives, panels and camera systems • Simple integration of fail-safe technology into drive & controller
Customer benefits
Cell stacking using 40 electrodes and 41 separator foils at maximum speed:
• Material handling in the µm range, A4 format • Positioning accuracy 100 µm
• 100% quality inspection for surface quality and position • Motion control with high dynamic jerk-free response • Time-optimized traverse paths
• Flexible cell format sizes • Integration into plant network
• Process visualization at the machine/in the control room
Requirements
M M M M M M Anodes Cathodes Separator foils Table with camera system Pick-up of electrodes/separators Virtual cross-hairsVacuum gripper with camera system PROFIsafe PROFINET PROFIsafe Machine automation Standard handling applications Motion control SIMATIC S7 (F) Cartesian gantry
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Documentation
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The core functionality is provided in the form of a library (SIMOTION) or a
function block diagram (SINAMICS DCC)
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Demonstration and test environment for familiarization
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Sample solutions for visualization
Components of the application
The Converting Toolbox is a library of off-the-shelf, tested, standard
applications for most conversion requirements.
It can be easily modified and freely combined to meet the respective
requirements of the machines.
Converting Toolbox
Applications in battery manufacture
Advantages of the Converting Toolbox
Converting Toolbox
Achieve the perfect converting solution in record time
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Time saving for commissioning and service
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Transparent and tested software
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Global APC support
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Open source for simple adaptations
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Solutions for SIMOTION, SINAMICS and SIMATIC
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The applications are free
Roll-to-sheet Roll-to-roll
Winding Tension control
Geschwindigkeits- oder Closed-loop speed or position control
Converting Converting Cutting
Winding Cutting
Axis control Axial winder Belt store Autom. roll change Tension control
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Prospects for the battery market
3
•
Value added chain and process
10
•
Automation technology and
expertise
16
•
Linear integration and
connection to the control level
23
Automation solution
Fabrikautomatisierung
Totally Integrated Automation Industry Automation Portfolio
Flexibility Productivity Efficiency Industry automation Drive technologies ERP PLM/ MES PLC/DCS/HMI Sensors/low voltage Motors/drives MC/CNC
Process control systems
Low-voltage controls and distribution Process instruments Automatiion systems RFID systems Industrial communication HMI devices PLM software Manufacturing Execution Systems
Enterprise resource planning (ERP)
Interlinking of production systems Horizontal + vertical integration SCADA / DCS
Energy data
Production data Quality data
Order control MES system Product tracking
Mixing Coating Compression Drying Slitting/punching Formation
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The factory of the future means the integration of product and product life
cycle with Siemens PLM + Totally Integrated Automation
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Acquisition and evaluation of all important KPIs
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Tracking & tracing, reporting, plant availability (OEE)
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Powerful process and system diagnostics, security, Safety Integrated, use
of standard components
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Integration and openness on the basis of Profinet
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PROFIenergy for intelligent boosting of energy efficiency
Customer benefits
• Quality measurement and optimization
Typical KPIs coating: - Layer thickness measurement (+/- 1µm withα orγ radiation) - Area mass (homogeneity)
Typical KPIs assembly: - Electrode surface checking - Electrode edge quality
- Positioning of electrodes when stacking (100 µm)
• Productivity - Transparency - Plant availability - Identification of bottlenecks - Flexibility • Energy efficiency
Requirements
Anlage
The integrated range of products and systems for automation
in battery cell manufacture
Visualization
Control
Drives
Peripherals
Warehouse management SCADA/DCS control system MES/ ERPCoating Punching Cell assembly Addition ofelectrolyte Formation Aging Test/categorization
Mixing
Maintenance station
Data server
User clients Web-client
OS LAN (Ethernet) (optional)
High product quality requirements
–
Fault sources in the overall process, and suitable measuring procedures
Cell manufacture
Electrode manufacture
* Inductively coupled plasma mass spectrometry ** Gas chromatography
Fault
sources
Measuring
method
Mixing Coating Compression Drying* Slitting/punching*
1 2 3 4 5 6 Cell assembly 7 Addition of electrolyte 8 Formation/aging 9 Test/categorization
R R Contamination Proportioning Viscosity Drying Porosity Adhesion Layer thickness Edges Particles Layer thickness Porosity Cutting burrs Broken edges Dirt
High dynamic response Separating Stack position Dirt/burrs Blistering Proportioning Distribution Contacting Overcapacity/ undercapacity Radiometric Beta radiation Optical Camera Laser Mechanical Scales Physical Silas, rheology viscosity Chemical ICP-MS* GC** Mechanical Scales Optical Camera Laser Electrical High potential Impedance Current/voltage Pulse power Physical Tension: Zwick X-ray Optical Camera Electrical High potential Optical Camera
More transparency from the machine to the corporate level
Integrated communication between all machines and the control room
User-specific preparation of
all the relevant machine,
plant and product data
Linear integration makes an essential contribution to reducing costs while
simultaneously increasing the quality of the battery cells produced
Visualization, quality control, calculation of key statistics (KPI, OEE)
Adapter
SCADA /
MES system
Compression Drying Slitting/punching
Mixing Coating Cell assembly
Maintenance Machine availability Trends Visualization System diagnostics Reports Messages, alarms OEE / KPI view
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Prospects for the battery market
3
•
Value added chain and process
10
•
Automation technology and
expertise
16
•
Linear integration and
connection to the control level
23
The intelligent factory
Seamless product and production life cycle
Optimization, maintenance
Simulation
Manufacture Virtual commissioning
Produkt design
Product use/service Product requirements
digital
real
digital
real
Faster from the product idea to production
on the basis of an integrated chain of engineering tools
TIA
Automation
Design
Production
Totally Integrated AutomationFactory design
Product design
PLM
Product Lifecycle ManagementFast response to new product requirements
ProductProcedure Mechanical system Electrical system Automation
Yesterday Today Tomorrow
In series in series,
shortened by tools
parallel Process
level
Time Time Time
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Shorter implementation times due to integrated view of all stages of product
and production development
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Integrated chain of engineering tools that supports both digital product and
plant planning, as well as engineering and commissioning
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Throughout the entire life cycle of the product and the production system, all
the necessary information is available at all times
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Increased productivity and cost effectiveness due to innovative and efficient
automation and plant concepts
P la n n in g C o m m is s io n in g M e c h a n ic s
