A consortium of German research institutions and industry partners, including Siemens, the Karlsruhe Institute of Technology (KIT), and Fraunhofer FFB, has launched the EXINOS2 project to develop a new production system for battery cell stacking. The initiative, funded by the German Federal Ministry of Education and Research (BMBF) with 3.64 million euros, seeks to improve the efficiency and adaptability of battery manufacturing.
According to a statement from ACP Systems AG, one of the project’s participants, the EXINOS2 system concept is expected to “significantly improve the efficiency and flexibility of battery cell production.” The approach builds on prior research and aims to address challenges in existing stacking processes, such as discontinuous manufacturing and limited adaptability to different battery cell formats.
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Battery cell stacks are typically assembled by layering the cathode, separator, and anode—materials that include coated metal foils and specialized plastic films. Traditional manufacturing relies on multiple gripping mechanisms and rigid tools, leading to pauses in production and requiring new molds and retooling when switching between cell formats.
To address these limitations, the EXINOS2 project partners have developed a prototype system that introduces a continuous process by pre-assembling a composite of electrode sheets and separators before stacking. This method is designed to improve production efficiency. Additionally, the system is intended to be adaptable to different battery formats through software adjustments rather than mechanical changes. The approach relies on handling systems that can adjust electrode sheet sizes as needed.
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The project brings together various research and industrial partners. ACP Systems is responsible for manufacturing the prototype system, while BST GmbH will contribute a web-guiding and optical electrode inspection system for stacking accuracy. J. Schmalz GmbH is developing vacuum gripping systems, while Siemens is providing control and drive components alongside software solutions for digitalization. KIT’s WBK Institute for Production Engineering is focused on refining processes and developing a digital twin of the production system, while Fraunhofer FFB is working on system integration within an industrial and digital framework.
With battery production playing a role in energy storage and electric vehicle manufacturing, the EXINOS2 project aims to contribute to advancements in battery manufacturing technology. The system’s potential to streamline production while allowing for format flexibility may be of interest to manufacturers seeking efficiency improvements. Further developments from the project are expected as research continues.