Battery Manufacturing Case Study Highlights
Challenge
- Designing and building a new automated assembly system for cylindrical battery cell production.
- Meeting strict government funding deadlines that demanded rapid development and deployment of a reliable solution.
- Ensuring precision in processes like laser welding and hermetic sealing to meet safety and functionality requirements.
- Maintaining an ultra-dry environment to prevent moisture from igniting the lithium.
Solution
- Custom Automated System: Designed and implemented an assembly system for cylindrical battery cell production, including a custom RAM press for precise positioning and secure placement of components.
- Clean Room: Implemented a clean room environment that maintains a -40° dew point.
- Simultaneous Development: Worked on multiple project components in parallel, streamlining design, development, and assembly to meet tight deadlines.
- On-Site Support: Embedded an ATS engineering team at the manufacturer’s facility, providing ready technical support and training.
Results
- Met all government deadlines and secured critical federal funding ensuring project success.
- On-time delivery of assembly system with advanced laser welding and hermetic sealing for the efficient and reliable production of high-quality cylindrical battery cells.
- Real-time monitoring ensures system performance, confirming flawless assembly of cells with no shorts and proper electrolyte levels.
- Expanded production capabilities, helping to position the manufacturer as a competitive force in the battery production market.
Company
Electronics Components Manufacturer
Industry
Automotive & Energy Storage
Region
North America
Customer
A leading electronics components manufacturer specializing in lead-acid and lithium-ion batteries for automotive and grid energy storage applications.
Challenge
Overcoming Aggressive Timelines and Technical Hurdles in Cylindrical Battery Cell Production
The electronics components manufacturer faced significant scheduling challenges as they expanded into cylindrical battery cell production for the first time. This complex process involved starting from raw materials, creating the chemical deposition on substrates, and rolling and inserting them into cans. The project had an aggressive production schedule with strict deadlines tied to government funding requirements.
To succeed, the manufacturer needed an automation partner with the resources, facilities, and technical expertise to deliver a reliable solution under intense pressure. The company selected ATS Industrial Automation due to the team’s extensive experience and proven track record in similar high-stakes projects. The team had previously developed advanced laser welding and hermetic sealing techniques for a military initiative involving lithium batteries for guided missiles, demonstrating the ability to handle complex technical challenges and meet tight deadlines.
Solution
Comprehensive System Development for Cylindrical Battery Cell Assembly
The ATS Industrial Automation team designed and delivered a comprehensive automated assembly system tailored for cylindrical battery cell manufacturing. The process begins with receiving raw materials, which are rolled and placed inside canisters. A custom hydraulic press was developed to ensure precise positioning and secure placement of the cylindrical components. This press applies significant pressure to flatten the ends of the rolled-up lithium-ion material, creating a solid surface for laser welding the terminals.
The system features meticulous cleaning and preparation of the canisters to maintain a pristine environment before the rolled material is inserted and hermetically sealed to ensure safety and reliability. The team addressed the critical challenge of maintaining an ultra-dry environment by implementing a clean room with a -40° dew point, preventing moisture from igniting the lithium.
To meet the tight deadlines, the team worked in parallel on multiple project components, advancing design, development, and assembly simultaneously. This efficient approach enabled the team to deliver a reliable solution within the stringent timeline. To ensure a smooth transition, ATS embedded a dedicated team of engineers and technicians at the manufacturer’s facility for 4 months, providing startup support, supply chain support, training, and comprehensive documentation for ongoing maintenance.
Results
Achieving Efficient Production and Ensuring Long-Term Reliability
The final battery assembly system delivered exceptional results. It enabled the efficient production of cylindrical battery cells that met all government timelines, securing the manufacturer’s federal funding. The system’s reliability and precision are demonstrated through successful laser welding and hermetic sealing processes, which are critical for the safety and functionality of the batteries. The manufacturer can now produce high-quality batteries at the required rate, a testament to the effectiveness of the assembly system.
The system maintains a -40° dew point in the clean room, providing dry conditions for lithium-ion battery production. Real-time monitoring and testing continuously validate the system’s performance, confirming no shorts inside the canisters and the presence of electrolyte.
The project successfully met all critical deadlines, including design completion, equipment power-up, and final delivery, even under a demanding schedule. With ATS’s hands-on support, the manufacturer seamlessly transitioned the new system to the plant operators for high-quality battery production. This success marks a significant step forward in the company’s manufacturing capabilities and positions them for future growth in the industry.
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