Simulation of the stacking process in battery cell manufacturing

Battery-electric drives become increasingly important in the context of electromobility, which means that battery cell manufacturing is assigned a key role from a production science perspective. Battery cell manufacturing consists of a complex sequential process chain, whereby the individual processes significantly influence the subsequent process steps. Especially for single sheet stacking of the electrode separator composite, the shape of the electrode sheets and their tolerances have a decisive impact on the achievable stacking accuracy. To quantify the influence, a simulation for the stacking accuracy is presented. First, a finite element simulation model is developed that calculates the achievable accuracy within the stacking process based on the sub processes positioning and gripping. With the simulation model shape deviations of the electrode sheets and their impact on the stacking accuracy are investigated. It is shown that length and width deviations in particular, as well as unevenness in the electrodes have an enormous influence on the achievable stacking accuracy. With the support of the simulation model, the stacking process can be examined in detail with regard to tolerable electrode shape dimensions and the required tolerances for this process step can be defined. ... mehrThis leads to a significant scrap rate reduction, especially in the ramp-up phase, which directly contributes to a more sustainable production of battery cells.