EV BatteryManufacturing
Driving End to End EV Battery Manufacturing Process
Rockwell Automation’s Expertise on EV Battery Manufacturing
Rockwell Automation understands the commercial and technical requirements for both EV makers and related machine builders to drive integration and create differentiation throughout the entire process.
[ EV Battery Manufacturing Lifecycle ]
• Flexible and scalable on production lines for multiple types of products.
• Easy to change processfor mass-customization.
• Intelligent Conveyor system can increase CPM (Cells Per minutes) productivity up to 25CPM.
• Speed – Reduce cycle time in bottlenecks.
• Increase parts transportation repeatability (50µm).
• Less vibration and dust – Improve quality of Station Jobs.
• Less contamination – less dust and lubrication use.
• Energy saving - smaller layout reduces cost ofclean room operation.
Drive core value of EV battery manufacturers, machine builders and System Integrators to meet the requirements and deliver the project successfully.
Save engineering / maintenance cost to drive higher ROI of CAPEX investment
• Save energy cost by 30% and materials cost by 42%• Single controller to control up to 240 motors
• Reduce commissioning time, reduce downtime (MTTF*, MTTR*) and improve availability.
* MTTF: Mean Time To Failure, MTTR : Mean Time To Repair
FlexibleProduction
HighProductivity
IncreasedQuality
Minimizing Environmental Impact
Our Focus in Automation is ...
Expanding Our Information Solutions
at a glance
Our strategy is bringing The Connected Enterprise to life.We help industrial companies and their people be more productive byintegrating control and information across the enterprise.
FISCAL 2018 SALES
• Design• Configuration• Simulation
• Visualization• Historization• MES (Manufacturing
Execution System)
• Asset management• Network management• Predictive maintenance
• IoT platform• Analytics and Manufacturing
Operations Management• Augmented reality
EMPLOYEES COUNTRIES
$6.7B 23,000 80+
ARCHITECTURE & SOFTWARE
... Where Technology Differentiation and Domain Expertise Matter!
CONTROL PRODUCTS & SOLUTIONS
2 3
PLANNING
• Consulting• Process design• Supplier
engagement
DESIGN
• Specification development
• Automation libraries• Production
engineering
INTEGRATION
• Line integration• Network validation• Startup
engineering
LAUNCH
• Maintenance engineering
• Production reporting
• OEE/KPIs
OPTIMIZATION
• Predictive maintenance
• Production analytics• Production
acceleration
Formation
Electrode Manufacturing Process
Cell Activation Process
Degassing & final sealing
Charge / Discharge testing
Aging
Mixing
Coating
Calandering
Slittering
Roll formation
Separation, Stacking,
Tab welding
Cell filling & sealing
Anode Cathode
Cell Assembly Process
Overall Cost Reduction
Machines & Equipments for EV Battery Production Lines
Enabling Technologies & Portfolio Independent Cart Technology (ICT) overview
Rockwell Automation Linear Synchronous Motors – Independent Cart Technology
Historically, conveyance has incorporated chains, belts, gears and other mechanics. These solutions have limited flexibility, wasted energy and led to excessive maintenance costs. Independent Cart Technology replace these mechanical components with simple, effective software profiles redefining speed and flexibility in automation.
Benefits Independent Cart System Feature
Throughput Fewer mechanical components and linkages creates higher speed.Higher speeds (2.5 m/s) [5.6 mph] combined with fully controlled motion profiles for better carrier positioning.
Flexibility Each moving cart is controlled independently. Flexible mechanical pitch enable the machine to handle multiple package/format sizes at once with full control package.
Constant Carrier Tracking
Integrated track and trace System. Software controlled carts with precise cart positioning eliminate external sensing with complexed tracking solutions.
Increased Uptime
Elimination of mechanical linkages and components allow minimal number of moving parts. It reduces overall downtime, maintenance and energy consumption.
Simplicity Software controlled carts reduce need for components such as sensors, actuators, stops, etc.
ProductivityIncreased
Energy Savingswith Quality Up
Floor LayoutSavings
40% 20% 30%
Integrated Motion Control & Safety MagneMover® LITE
Differentiators
• Easy design and setup• “Erector set” modularity• Integrated merge/diverge• Integrated bearings• Customizable for IP69K and
hygienic design
Key applications
Small-sized battery, General Assembly
INTELLIGENT CONVEYOR SYSTEMS
Differentiators
• Higher thrust and speeds• Flexible layout with variable
motor spacing provides cost efficiencies
• Balance of standard and customer designed features
Key applications
Large -sized battery, Module pack assembly
QuickStick®
QuickStick® HT
iTRAK® Intelligent Track System
Differentiators
• Highest thrust• Capable of moving 5000 kg+• Different size options add
flexibility• Can be hermetically sealed
and operated underwater
Key applications
General EV battery application
Differentiators
• Deterministic closed loop servo performance
• Automatic synchronization with other motion axes
• High dynamic performance and force
Key applications
Small & large-sized battery, General Assembly
We understand machine builder challenges and deliver high-performance motion control systems and integrated safety solutions to help meet your meet your goals.
Simplify machine design while improving overall performance
• Integrated motion with safety (Safe Torque Off)
• Servo drives and motors
• CIP Security in network communication
• Adaptive tuning
MotionControllers
• Logix based scalable multi-disciplined control
• Scalable up to 2 - 100+ axis
• Single software for multiple motion & safety control
• Integrated safety & CIP Security over EtherNet/IP™
Single architecture to control the machine and system
Integrated Safety
• Single platform for safety logic, I/O and component
• Contemporary technology to improve equipment productivity
• Safety consulting to assess, design, and validate safety system
Less unscheduled downtime and more protection for operators
Permanent-Magnet Array
QuickStick Motor
Pallets or Puck
Node Controller
DC PowerSupply
PowerCable
Serial Comm.
Host PLC or PC
Ethernet
Traditional Conveyance vs. LSM (Linear Synchronous Motors)
Customized lengths, not scalable or modular HARDWARE Highly Scalable & Modular
Typically slow. Constant and variable speed when using VFD (Variable Frequency Drives)
THROUGH PUT(Velocity, Acceleration)
Faster acceleration station to station (2.5 m/s) [5.6mph] and 9.8m/s² [1.0g] Multiple modes: Indexing, synchronous, a-synchronous –
Crude simulation, requires precise knowledge of line, each intersection requires station programming (PLC)
TIME TO MARKETFull line simulation: High speed single part or batch transfer. Built in track and trace capabilities
PC based. Pre-determine moves, decision points & stops and starts required
SOFTWAREComprehensive code libraries. Reduction of program complexity, ideal for complex vehicle routing. Anti-collision & automatic queing built-in
Large radius curves. Requires buffer zones to meet similar Magnemotion throughput
FLOOR SPACE20% to 30% reduction in floor space = more production / sq-meter. No need for buffer zones
Conveyor is costantly moving. Motors are fully engaged when power is on. Saves energy when VFD is used
ENERGEY EFFICIENCY
30% to 40% reduction in power consumption - inactive components do not draw power.
100's of moving parts, belts/chains require tightening. Significant spares inventory.
MAINTENANCE & RELIABILITY
No moving parts, higher machine reliability, highest OEE (Overall Equipment Effectiveness) available.
Creates dust and debris.Lubrication is necessary.
CLEANLINESS No particle generation, frictionless, contactless and clean
Traditional Conveyance vs. LSM (Linear Synchronous Motors)
Technology Comparison
4 5
Scalable Analytics by IIoT platforms
Augmented Reality Use Cases : 42% Reduction per Issue
• Reduce dependency on traditional paper manuals, and add ability to update instructions remotely
• Overlay maintenance instructionson how to repair and replace components
▶ 33% reduced downtime
• Operators of machinery can viewan overlay of performance dashboards & manufacturing instructions
• Interactive and situational training that overlays 3D instructions for job tasks in a safe and secure environment
▶ 50% reduced downtime
• Remote service technicians can rapidly access critical information and enable collaborative solutions
• Allows you to “see what I see” andannotate in a shared workspace leveraging Vuforia Chalk
▶ 50% reduce downtime
Digital Engineering
Smart Connected Machine Solutions
Maintenance workflows Enhanced Operations Remote Assistance
Reduce Costs
Throughput Analysis Machine Prototyping Virtual Commissioning Operator Training Systems
Improve Revenue
Reduce Risks
Add Value
Global competitiveness
The changing globallandscape requires OEMs to reduce the overall capital cost of their equipment to remain attractive.
Analytics
Improving process, quality and
performance
Smart Sensors
Enhancing tracking of materials, people, consumables and
emissions
Mobility
Reducing maintenance costs and improving
personnel productivity
Simulation
Reducing validationcosts and testingengineering ideas
before implementation
AI & Machine Learning
Predicting failuresand increasing yield
AR/VR
Improving collaboration and
making operations safer
Machine as a service
New collaboration technologies allow significant benefit to end users productivity and quality, building stronger relationships between OEMs and end users, and opening up new potential revenue streams for OEMs.
Project & Operational Risk
Highly publicized and expensive incidents worldwide have raised awareness of equipment development and operational risks. OEMs are challenged with mitigating these risks throughout the entire machine lifecycle.
Industrial Internet of Things (IIoT)
OEMs are faced with navigating new IIoT solutions to bring additional value. A crowded market place creates difficulty in sourcing skilled workers and reliable technology partners.
Smart Connected Machines Enhancing support for your end users by collaborating through the equipment’s entire lifecycle
DIAGNOSTICWhy did it happen?
Market-leading industrial innovation
platform to drive digital transformation for
increased operational performance and agility across all
factories
Industry-Leading augmented reality development tools
to improve workforce efficiency and
training
A set of tools built on top of our FactoryTalk
ProductionCentre MES Platform that
target specific needs of Manufacturing
Operations: Performance, Quality, Production &
Warehouse
Self-service visual analysis/ Data Discovery
tool. With Insightful Storyboards may be
saved and shared that runs on any form factor
or device
Data from real-time sources, with the ability
to store and forward data, reducing loss due
to latency. Enables closed loop feedback
applications and provides advanced analytics in the
“hardware stack”
Solve complex Analytics, AI and Machine Learning
problems. Scalable from on-premise
server to cloud based infrastructures. Handles big data and unstructured
data such as text, imagery, audio, etc.
PREDICTIVEWhat will happen?D
ATA
PRESCRIPTIVEWhat should I do?
IOT AR Fit for Purpose Data Analytics Edge Computing Analytics and AI
DemonstrationCreate dynamic system models rapidly with supplied generic objects and imported CAD.
Generate impressive videos and even demonstrate operating systems within a Virtual Reality environment.
SimulationAnalyze system throughput, identify bottlenecks, dimension resources appropriately and understand the system response to operational changes.
Reduce the investment risk with repeatable experimentation.
Virtual CommissioningTake controls testing off the project’s critical path by connecting an accurate dynamic model of the machine or system to real controls.
Verify the logical operation of the controls offline, before building the real system.
6 7
PanelView HMI / FTView SCADA
FT Analytics for Devices
ICM Dynamics
FT Historian & VantagePoint
LogixAI
FT Analytics DataView
Asset Advisor
Analytics
CLOUD / HYBRID / ON-PREMISE
WarehouseManagement
QualityManagement
CPG
PerformanceManagement
IOT Analytics ThingWorx
Rockwell Automation can help you solve your EV battery manufacturing challenges so you can streamline your production line and get the best value for ICT and automation investments.
Supporting Your Business Every Step of the Way
Industry Focused OEM Team
Your reputation rests on building machines and equipment that meet customer demands. Our technical consultants, engineers, and project managers can help you solve key issues and differentiate your company in a competitive global environment.
PartnerNetwork
PartnerNetwork™ members are leading companies that have experience delivering products or services that are designed to work with our solutions. The collaboration among members helps streamline your supply chain, simplify project implementation, and receive the best value for your automation investment.
Providing global support with a local address Helping customers around the world maximize productivity and minimize risks
Training and Support
As your equipment lifecycle changes, so does your need for technical support. We give you the flexibility to choose the level of electronic and phone support you need, when and where you need it. From service to risk assessments, we provide training and support through the entire lifecycle of your automation equipment.
Global Services & Support
24x7x365“Follow-the-sun” SUPPORT
2,600+SERVICE PROFESSIONALS100+ Consultants700+ Field Services Professionals
80+COUNTRIES12 Remote Support Centers18 ISO-Certified Repair Centers 9 Exchange Hubs
19LANGUAGES SUPPORT
200+TRAINING COURSES
13+ YearsAVERAGE EXPERIENCE
Publication OEM-BRO25A-EN-P - October 2019Copyright © 2019 Rockwell Automation, Inc. All Rights Reserved.
FactoryTalk, iTRAK, MagneMotion, MagneMover, PartnerNetwork and QuickStick are trademarks of Rockwell Automation, Inc. Rockwell Automation are registered trademarks of Rockwell Automation, Inc.
EtherNet/IP are trademarks of the ODVA. All other trademarks and registered trademarks are property of their respective companies.