BatCO₂tiv – Battery Interconnection: Automated, CO₂-Reducing, Collaborative

Sub-Project: Process Development and Process Evaluation for Projection Welding

Duration: 06/2023 - 05/2026
Contracting Authority/ Sponsors: Federal Ministry for Economic Affairs and Climate Action (BMWK)
Project Partners: Smart Battery Solutions GmbH
Project Focus:       
The automatic welding cell with robot and inverter enables precise micro projection welding of battery cells.
© Fraunhofer ISE
The automatic welding cell with robot and inverter enables precise micro projection welding of battery cells.

Efficient battery storage systems compensate for fluctuations in renewable electricity production, electrify the transportation sector and supply consumer electronics with portable energy. Battery cells require interconnection, which is why the automation of battery storage production is an important step towards lower CO₂ emissions, higher quality, lower costs and maintaining value creation expertise in Germany. The challenges of this production lie in short process times, flexibility and process monitoring. The project therefore uses collaborative robots for human-machine interaction and non-invasive methods to evaluate the interconnection processes and electrical interconnection quality.

Setting up a multi-mix split line and increasing production capacity

The BatCO₂tiv project has the overarching goal of establishing an innovative and collaborative multi-mix split line for the flexible automation of the production of the UniPower product family at Smart Battery Solutions GmbH. By developing concepts for all production steps, design rules for cell connectors and cell holders are derived to create a pack design that can be processed with collaborative robots. By reducing the production time per welding point to less than 0.6 seconds, a multiplication of the number of units is to be achieved.

Reducing CO emissions and developing sustainable products

An important goal of the project is to reduce CO₂ emissions in production through faster and more stable manufacturing. In addition, the CO₂ reduction of products for last-mile delivery, e-scooters, sharing systems and e-bikes is to be made possible. This contributes to the implementation of the energy transition and promotes sustainable energy storage.

Improving product quality and process control

A detailed characterization of the joints ensures optimal further development of the UniPower product family. The project also aims to increase the service life of the welding electrodes by developing optimized, intelligent process control. The correlation of the welding parameters with the joint characterization data is a further objective.

Evaluation of non-invasive methods and strengthening the business location

As part of the project, non-invasive characterization methods for spot welds are being evaluated in order to enable inline process monitoring. The aim is to improve the efficiency and quality of the joining processes. At the same time, the project aims to strengthen Germany as a business location by reducing costs and maintaining value creation expertise.

More Information on this Topic:

Research Topic

Battery Engineering

Business Area

Electrical Energy Storage