The EXINOS2 project aims to develop and industrialize a prototype production system for optimized stack formation in battery cell manufacturing. Funded by the German Federal Ministry of Education and Research (BMBF) with €3.64 million, the initiative focuses on enhancing both the flexibility and efficiency of battery cell production.
Researchers from the wbk Institute for Production Technology at the Karlsruhe Institute of Technology (KIT), the Fraunhofer Research Facility for Battery Cell Manufacturing (FFB), and industry partners including acp systems AG, BST GmbH, J. Schmalz GmbH, and Siemens AG are collaborating to advance the prototype system. Building on previous research, the innovative production concept leverages new technologies to significantly improve the manufacturing process of battery cell stacks.
Traditional methods of assembling battery cell stacks involve multiple automated gripping actions and rigid tools, which create interruptions and make the process discontinuous. Additionally, the use of format-specific tools complicates the production of different battery cell formats, requiring costly tool changes and time-consuming reconfigurations when introducing new formats.
The EXINOS2 prototype addresses these challenges by creating a composite of separator and electrode sheets prior to the stacking process, enabling a continuous and faster production flow. The system’s technology is designed to be format-flexible, allowing for rapid software-based adjustments to accommodate new cell formats. This flexibility is achieved through adjustable handling systems that also facilitate the cutting of electrode sheets.
By improving the efficiency and adaptability of battery manufacturing in Germany, the project is expected to play a crucial role in the energy transition. Enhanced production capabilities present significant opportunities to boost economic strength, foster technological innovation, and support the expansion of the electric mobility sector.
Over the three-year duration of the project, all subprocesses of the prototype system will be further developed and tested to meet industrial standards for series production. The integration and testing of alternative technologies within the system are also planned. Digital methods are integral to the project, with the development of a “digital twin” simulation tool that optimizes component placement within the machinery. This digital twin is expected to accelerate system commissioning and provide valuable insights for machine operators during production.
The EXINOS2 project is scheduled to run from January 2025 to December 2027, with ongoing support from the BMBF to achieve its objectives of advancing battery cell production technology.
Source: ACP Advanced Clean Technology
