EXINOS2

Brief Description

In the EXINOS2 project, the technology readiness level of an already implemented prototypical and innovative machine concept (called EXINOS) for flexible and continuous stack formation is to be increased. The system is to be further developed into a functional system and tested in a production environment close to reality. The aim of the system is to significantly optimize the stacking process step in terms of flexibility, throughput capacity, and footprint.

The stacking process step is attributed high importance within the battery production chain. Not least because a transition from a continuous to a discrete process usually takes place here, resulting in challenges such as increased susceptibility to errors, complex handling processes, and increased effort with regard to intralogistics. The “Pick & Place” systems used so far are limited in terms of throughput and the cell formats to be produced.

For this reason, the singulation, cleaning, composite construction, stack formation, web guiding, and handling modules are to be technically optimized, coordinated with each other, and combined through a scalable control framework. In parallel, a digital twin will be developed to enable virtual commissioning, evaluate operating data, and support virtual condition monitoring.

The machine is to be integrated into the infrastructure of the research production facility and tested under real production conditions. Accompanying project and knowledge management will ensure that the objectives are achieved on schedule and will prepare the developed methods as a blueprint for future industrialization projects in battery cell production.

The work plan comprises six work packages:

WP 1: Based on market and technology analyses, requirements for throughput, flexibility, footprint, as well as physical and digital interfaces of a series-production-ready stacking machine are defined. This includes integration into industrial process chains with IIoT/MES connection and the specification of the digital twin. Targeted optimizations for singulation and stacking technologies are derived from the EXINOS concept.

WP 2: Based on the requirements from WP1, the overall system concept is created. Material flow, subprocesses (singulation, cleaning, composite build-up, stack formation, web guiding, handling), as well as measurement, drive, and control technology, are designed and linked into an industry-capable system. Prototypical tests of individual modules ensure performance, process stability, and digital integration capability.

WP 3: A model-based digital twin is developed. After defining requirements, interfaces, and the development pipeline, physical sub-models are created, which are coupled for virtual commissioning and parameter optimization. Real-time connection to PLC and edge systems enables optimizations for development, commissioning, and operation.

WP 4: Assembly of the modules developed in WP2 into the overall system at the FFB, ensuring physical and digital compatibility with the existing infrastructure.

WP 5: Validation of the overall system through test campaigns (stack and full cell assembly, quality and electrochemical tests). The results are compared with the digital twin. Optimizations derived from this are implemented in the system to increase efficiency and performance.

WP 6: Project support with continuous target review. The acquired know-how is prepared as a blueprint for future transfer projects and the industrialization of prototypical systems

The project consortium combines the scientific expertise of Fraunhofer FFB and the wbk Institute of Production Science at KIT with the industrial experience of acp, BST, Schmalz, and Siemens. Through the complementary fields of expertise within the consortium, all competencies required for construction, further development, and implementation are covered. The focus is on optimizing the stacking process, which still offers considerable potential for improvement.

By the end of the project in 2027, a production-ready system is to be developed and secured by patents. In order to establish and strengthen Germany as a location for battery production in the long term, strategic options for sales and further development will be examined. This will create sustainable competitive advantages for German mechanical engineering, component manufacturers, and digitalization enablers.