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.
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.
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 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.
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.
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.
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.
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.
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.
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.
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 a highly automated production for you, taking strict account of all requirements.
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.
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.
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:
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.
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.
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 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.
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.
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.
After the completion of our projects, we analyze the results and derive further improvement measures. We enable rework fast, reliably, and with non-destructive measures.
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:
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.
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 concepts, 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.
Ask us. Please send us a message. We would be happy to hear from you.
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