Cengiz Özemli
Academic
- Thread Author
- #1
With the rise of electric vehicles, battery and electric motor production has become more critical than ever. To optimize production processes in this field and ensure a transition to full automation, pneumatic and electric drive solutions offered by pioneering companies like Festo are of great importance.
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🏭 Transition to Full Automation in Electromobility Production
The production of electric powertrains is evolving from traditional semi-automatic methods to fully automated industrial configurations. While global electric vehicle production is expected to increase by 30% annually until 2030, battery cells account for approximately 40% of the vehicles' added value. In Europe, battery production capacity is projected to rise from 6% to 25% by 2030. This growth indicates that automation in production processes is indispensable.
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🔬 Cleanroom and Dry Room Requirements
The production of electric powertrains, especially for battery cells, entails strict environmental requirements such as cleanrooms and dry rooms. Quality regulations like VDA 19 are applied to prevent metallic particle contamination in production processes. Automation components must comply with these standards. More than 80 product series from Festo are certified for ISO Class 7 controlled environments, with Class 6, 5, and 4 compliant models also available.
[]This level of cleanliness is achieved through the use of reinforced polymers (GRP/CFRP) and over 60 anhydrous lubricant formulations.
[]Materials containing copper, zinc, or nickel are entirely removed from metallurgical design to prevent chemical degradation of the cells.
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⚙️ Processing Systems and Degassing Processes
In the stages following the initial electrical contact of battery cells, automation manages critical operations. These include processes such as piercing and forming gas extraction. Degassing and sealing processes require high geometric precision and repeatable cycles. In these stages, integrated compact spindle axes with dual guides are used.
The assembly of battery modules and packs requires flexibility due to variable geometries and fluctuations in production volume. Standardized drive technology optimizes spare parts availability while reducing machine downtime. The combination of pneumatic and electric vectors, such as pneumatic cylinders, integrated position encoders, mechanical safety brakes, electric cantilever axes, and special servomotors, ensures robust handling of the cells.
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🛡️ Functional Safety and Decentralized Control
During module assembly, functional safety is ensured by pneumatic rotary actuators that perform active cell locking. Optical sensors detect mechanical alignment during the cycle, while the IO-Link interface enables logical parameterization. Electrical polarity control ensures automatic removal of incompatible components.
The control architecture is based on a decentralized logic to maximize OEE (Overall Equipment Effectiveness). Automation systems with motion control based on the CODESYS V3 standard reduce the computational load on the main controller. This facilitates peripheral data processing and the integration of devices into a transparent automotive data ecosystem. This approach supports the creation of digital twins for simulation and interfacing with specialized learning platforms to enhance the technical competence of workshop personnel.
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📊 Competition and Innovation
Lithium-ion battery cell production introduces strict industrial standards to prevent metallic particle contamination. The controlled exclusion of copper, zinc, and nickel is a key competitive parameter among pneumatic and electric system manufacturers. Competitors like SMC offer copper and zinc-free actuator and valve series, while Bosch Rexroth provides modular chain transfer systems and linear guides with special surface treatments. Omron, on the other hand, focuses on traceability and synchronized control of stacking systems. Festo's solution offers compliance up to ISO Class 4 for over 80 standard product ranges, reducing the need for system integrators to develop custom variants and securing a strong position in the market.
