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  • Elementary component of electric vehicles
  • The battery

    Elementary component of electric vehicles

Batteries for electric vehicles

You can’t do without it: The battery is the central component of an electric vehicle, because it is the energy source for the drive. The battery not only determines the range a vehicle can cover, but also the charging time. At the heart of every battery are the battery cells, which account for most of the value added.

 

These cells are based on lithium-ion technology, which is characterized by a high energy density and thus a long service life. This enables a large number of charging cycles. However, production requires materials that are difficult to process, and in some cases highly hazardous. Whether developing, producing or transporting lithium-ion batteries, many laws and regulations have to be taken into account.

Opportunity provider and challenger at the same time

Thus, for car and battery manufacturers, the battery represents an enormous opportunity on the one hand, and a major challenge on the other. Today, electric vehicles tend to have a greater range, but the industry is under enormous pressure to further reduce costs while at the same time increasing performance. This is a gap that needs to be bridged for car and battery manufacturers, because even today battery production is still new territory for many OEMs.

Shaping tomorrow’s electromobility together

Leadec has been gaining experience and proving its expertise in the field of electromobility for years. We’re on home territory in the world’s automobile plants, having been involved in planning and automating many facilities for major OEMs and we have been maintaining them throughout the years. Whether you are producing combustion engines or electric motors, conventional powertrains or battery assemblies – with our technical services as well as excellent planning know-how we are the ideal partner for the cell factory.  

 

Full range of services at every step

When it comes to battery manufacturing, Leadec is at your side as a competent full-service provider. From battery cell production to the creation of emergency concepts to ensure the reliability of your production – we guarantee a sophisticated solution approach for each of your process steps.

 


Our battery manufacturing process steps at a glance:

1. Battery cell production

We design your battery cell production with hazardous raw materials to be as safe as possible. We pay attention to a high energy density and performance of the cells. Furthermore, a long service life and a high number of charging cycles is our top priority – and all this with the highest degree of automation.

Our services in the field of battery cell production

Engineering

  • Rough, detailed and realization planning with a view to production sequences
  • Concepts for logistics planning incl. hazardous materials
  • Process optimization especially at the line for more output and better efficiency

Automation

  • Installation and commissioning of the line
  • Emergency & fire protection concepts, early detection
  • PLC programming
  • Automated picking of the finished cells

Production IT

  • MES system for improved production control
  • IT-based quality inspection
  • Inline measurement test systems

Prototypes

  • Creation of prototype cells for product and process validation with regard to cell chemistry

We offer you:

  • innovative solutions from a single source,
  • a first-class team,
  • a global network with industry focus,
  • customer proximity,
  • and technical expertise

2. Battery module assembly

The assembly of the cells must be carried out in compliance with strict safety rules. We realize your battery module assembly with the highest possible degree of automation and optimized output. You can rely on us to meet the strict safety standards in every respect.

Our services in the field of battery module assembly

Engineering      

  • Realization planning
  • Production and component planning incl. concept creation
  • Rough, detailed and realization planning
  • Validation of the planning by means of digital twin
  • Test concepts and process documentation incl. validation

Automation

  • Installation and commissioning of the line
  • Emergency & fire protection concepts, early detection
  • PLC programming
  • Automated picking
  • Commissioning

Production IT

  • MES system for production control
  • IT-based quality inspection

Our references:

For the world’s largest automotive manufacturer, we took over the planning and construction of the fully automated modular electrification toolkit HV battery assembly and also designed a comprehensive testing concept. In addition, Leadec coordinated the development-related planning services for the joint venture partners and provided on-site support for the planning, construction and commissioning of the modular electrification toolkit HV battery assembly.


3. Battery component assembly

Complex assembly processes are the core area in the modern fabrication of battery components or even entire systems. We at Leadec Automation & Engineering guarantee process-reliable assembly of the individual modules for ideal component performance with the highest degree of automation.

Our services in the field of battery component assembly

Engineering      

  • Realization planning
  • Production and component planning incl. concept creation

Automation

  • Installation and commissioning of the line
  • Emergency & fire protection concepts, early detection
  • PLC programming
  • Automated picking
  • Commissioning

Production IT

  • Seamless documentation of the production steps
  • MES with employee guidance
  • Quality inspection with connection to higher-level systems incl. evaluation of data
  • Derivation of deviations & identification of trends in production

Our references:

The largest commercial vehicle manufacturer in the world commissioned Leadec to plan out its entire battery assembly process. From layout and shift model creation to storage and empties management to quality assurance and traceability for permanent, process-reliable availability of the complete plant.

Leadec realized a second successful project with a manufacturer of lithium-ion battery systems. The aim was to assemble the individual components in such a way that the end result was a compact battery housing with high-performance components and fail-safe processes. We were able to complete this project successfully and to the customer’s complete satisfaction.


4. Battery housing production

The requirements for a battery housing are complex: The battery must be crash-proof in the event of an accident, but it must also have optimum sealing against external influences such as water and dust. This requires a complex overall system consisting of mechanical protection devices, integrated cooling and electrics. We create highly automated production for you, taking strict account of all requirements.

Our services in the field of battery housing production

Engineering      

  • Selection and concept creation of joining and manufacturing technology
  • Assembly process planning
  • Process optimization

Automation

  • Installation and commissioning of the line
  • PLC programming
  • Process commissioning

Production IT

  • MES system for improved production control
  • IT-based quality inspection, especially for tightness
  • Digital quality monitoring of weld seams

Prototypes

  • Creation of prototype cells for product and process validation

Our references:

We were involved with our full scope of services in the design, planning and implementation of the assembly line for battery housing production at one of the largest premium car manufacturers. As part of the assembly process, our services contributed to the creation of the first all-electric vehicle. The pre-assembly of eleven different components demanded the highest performance from us in the shortest possible time.


5. Battery pack assembly                                                                                                                               

Flexibility, data communication, a high level of reliability and a wide range of variants are requirements for the materials handling systems in the battery pack assembly. We design your production processes to be effective, reliable and trouble-free.

Our services in the field of battery pack assembly

Engineering      

  • Realization planning
  • Production and component planning incl. concept creation
  • Rough, detailed and realization planning especially for screws used in assembly
  • Planning of processes and ensuring their reliability, e.g. for flow-drilling screws
  • Concept and realization planning for the handling of non-rigid components

Automation

  • Installation and commissioning of the line
  • Emergency & fire protection concepts, early detection
  • PLC programming
  • Automated picking
  • Commissioning

Production IT

  • Seamless documentation of the production steps
  • MES with employee guidance
  • Quality inspection with connection to higher-level systems incl. evaluation of data
  • Derivation of deviations & identification of trends in production

Our references:

We have implemented two major projects for a German premium car manufacturer. One was the planning and installation of automation and screwdriving equipment in the high-voltage battery assembly. Our scope of services included the realization of the materials handling system with robotic systems and the implementation of programmable logic controllers as well as the installation of grippers and positioning devices. As a full-service provider, we also took care of the preparation of hazard analyses and the design of storage, logistics and emergency concepts.

Another order focused on layout planning and commissioning of production equipment for automated prototype production in the HV battery assembly and in-house production of cell modules.

In another project, we supported a leading manufacturer of high-performance battery systems in the planning and preparation of tender documents for the logistics and associated logistics resources for a new assembly line. All important assembly steps and process data sheets were conceptualized by us. The focus was on the optimal storage and transport design for more productivity and included the following sub-services:

  • Warehouse planning for purchased parts and battery assembly modules
  • Planning of material flow and storage levels
  • Determination of space requirements for logistics areas
  • Layout of racks and logistics areas
  • Determination of loading equipment for material transport
  • Definition of required resources for transport
  • Determination of required personnel

6. Quality control

To guarantee the quality of battery assembly, we ensure the availability of your complete plant and equipment. Our service includes production equipment maintenance for assembly lines on which batteries are assembled and the associated automated guided vehicles.

Our services in the area of production IT

Smart factory/assembly

  • Web-based ANDON boards
  • Line information & piece counts
  • Current production trend
  • Malfunction displays
  • Workstation-related employee guidance
  • Parts lists
  • Work instructions & quality notes
  • Localizable languages

Smart factory/shop floor monitoring

  • Flexible identification and presentation of KPIs
  • End-to-end interfaces from the shop floor to database servers
  • Web-based interfaces for easy display of dashboards

Smart factory/logistics​

  • Precise line-side material supply
  • Transparency of components for the production process
  • Flexibilization of kanban processes for last-minute adjustments
  • Connection of central ERP and logistics systems
  • Linking of automated guided vehicles with central control station
  • Support for workers through a consistent, scalable and mobile assistance system

Our references:

We have developed an integration tester in accordance with DIN EN 50128. This European standard describes the requirements for functional safety in the railroad industry.

Our scope of services included the real-time model-based simulation of systems and components for software development and the setup and execution of an integration test for safety controls. Furthermore, we participated in the creation and automated execution of the residual bus simulation of the entire train and of several test sequences. We also created the connection of test cases and the associated reporting based on Microsoft Team Foundation Server.

 

Everything under control at all times

With our internally developed product welD.One for digital weld seam monitoring, we are able to improve the production quality significantly. Our software solution guarantees an optimal display of the current welding data and a permanent quality control in the production.

We would be pleased to implement this intelligent system for the acquisition, recording and evaluation of inline quality data of weld seams also at your plant.

 

Learn more about welD.One


7. Vehicle assembly

The battery is not only the most important component of an electric vehicle, but also expensive to manufacture. We ensure a smooth, process-reliable and automated installation of the finished battery into the vehicle. 

Our services in the field of vehicle assembly

Engineering      

  • Plant and joining station design
  • Process and production planning

Automation

  • Installation and commissioning
  • PLC programming

Production IT

  • Seamless documentation of the production steps
  • MES with employee guidance
  • Quality inspection with connection to higher-level systems incl. evaluation of data
  • Derivation of deviations & identification of trends in production

Our references:

The world’s largest automotive manufacturer contracted Leadec to assemble the batteries in two of its first fully automated electric vehicle models. Our task was to optimize the assembly process to ensure smooth battery and cable installation. Our services included wedding planning and the associated pre-assembly as well as precise detailed and realization planning and support.


8. Battery rework

After the completion of our projects, we analyze the results and derive further improvement measures. We enable rework fast, reliable, and with non-destructive measures. 

Our services in the field of battery rework

Engineering

  • Design of the rework stations
  • Concepts for the fault correction process
  • Validation of the concepts

Automation

  • Installation and commissioning of the line
  • Emergency & fire protection concepts, early detection
  • PLC programming
  • Commissioning

Production IT

  • Checking of parts and components for usability
  • IT-based conclusions on source of defects with ERP connection
  • Checking the quality of the rework

Our references:

One of the world’s leading and largest manufacturers of chassis components made use of our services in the field of battery rework. The central task included the conceptual planning of the stations with regard to:

  • Workplace design
  • Layout planning
  • Creation of tool lists and corresponding recommendations
  • Test concept and strategy creation
  • Proposals and planning of lifting tools for the workplace

9. Emergency concepts                                                                                                                                  

The lithium in batteries creates a high energy density. However, it is a potentially dangerous cell system due to its high reactivity. We ensure maximum safety – early, consistently and reliably.

Our services in the field of emergency concepts

Engineering

  • Concept development
  • Hazard analysis
  • Fire protection concepts
  • Early detection and catalog of measures

Automation

  • Acquisition of production data for early warning as well as future error prevention

Our references:

An automotive manufacturer in the premium sector commissioned us to prepare a hazard analysis concept, including the development of suitable fire protection measures and the implementation of an emergency concept in accordance with regulations.

Initially, we provided support in the needs assessment and advice on suitable occupational health and safety measures, such as the purchase of safety clothing for optimum protection in everyday working life.

 

In the area of conception, we took over the complete elaboration of different processes and measures of action in case of fire or emergency. Leadec planned the implementation of a CO2 extinguishing system and special rooms, which were equipped with adequate containers for emergencies.

Another major part of the project involved the creation of a customized storage and logistics concept for safe storage of the modules, taking into account temperature measurement data as well as sensible and efficient management in the area of incoming and outgoing goods.



Leadec Automation & Engineering GmbH

 

Meitnerstraße 11
70563 Stuttgart

 

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