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Research project to accelerate battery production
The EXINOS2 project's approach brings several innovative new features to the production of battery cell stacks. A continuous production process, format-flexible system technology and increased precision and quality are intended to raise the process to a new level. But how do the processes of the joint project differ from conventional battery cell production methods?
Innovations of the EXINOS2 project
A brief look at the current battery production process shows the challenges that the EXINOS2 project aims to address: when manufacturing battery cell stacks, the cathode, separator and anode must be stacked precisely on top of each other. While the anode and cathode are coated metal foils, the separator is usually a special plastic foil. The standard production process relies on automated gripping processes and rigid tools. However, this method automatically causes interruptions in the process, which makes the process discontinuous. According to a press release from one of the companies involved, ACP Systems AG, the format-bound tools are also very inflexible. As soon as a new battery format is to be produced, cost-intensive new moulds and time-consuming retooling work are required.
The EXINOS2 approaches developed in the prototype are intended to solve precisely these problems. A decisive step is the development of a composite of electrode sheets and separator, which takes place before the actual stacking process. This enables continuous and therefore significantly faster process control. At the same time, the system technology is designed in such a way that software-based switching to other cell formats can take place within a very short time. This is to be made possible in particular by flexibly customisable handling systems - i.e. components that precisely cut the individual electrode sheets to size.
Contributing to the energy transition and the development of electromobility
The EXINOS2 partners are pursuing the goal of making battery cell production in Germany more economical. More efficient and flexible production should make a significant contribution to the energy transition and at the same time strengthen the competitiveness of German industry. The Federal Ministry of Education and Research (BMBF) is supporting the project with 3.64 million euros.
In addition to the scientific partners KIT and Fraunhofer FFB, several industrial companies are involved in the realisation and are taking on various tasks: ACP Systems AG, for example, is developing the target system and BST GmbH is providing a solution for web guiding and optical electrode inspection, with a focus on the stacking accuracy of the electrode sheets. J. Schmalz GmbH is working on innovative vacuum gripping systems. Siemens is also involved and is developing hardware and software solutions, while the WBK Institute for Production Technology at KIT is researching digital twins and optimising sub-processes. The Fraunhofer FFB provides the infrastructural framework for integration into industrial production.
Image: KIT, Amadeus Bramsiepe
Source: electrive.net, Sebastian Schaal, 20.02.2025