Showcasing their latest advancements in battery systems, Bosch Rexroth’s automation technologies are prominently featured at the Michigan CIC, with a centrally located Battery Module Demonstration Room. Resembling a pilot line, this room features a broad spectrum of Bosch Rexroth technologies from its automation portfolio, covering cell production, modular assembly, and end-of-line testing, among other functions.
Process Reliability
Various types of batteries necessitate distinct production methods for converting electrode films into cell elements. Whether it’s pouch cells, prismatic cells, or cylindrical cells, high dynamics and precision are essential for separating or stacking the cathodes and anodes. Bosch Rexroth boasts deep expertise in dry room and clean room production, including long-term component testing, ensuring high-quality standards and reliable production processes.
Technologies on Display for Cell Production:
- VarioFlow plus Conveyor System:
- A tight turn radius minimizes tool footprint.
- Swift and efficient transportation of cells within process stations and between machines
- Items can be conveyed either on pallets or directly on the conveyor system
- Configurable for utmost design flexibility, handling high-volume products horizontally, vertically, and around obstacles.
- Rexroth Flexible Transport System Pallet Boost:
- A highly dynamic transfer system propelled by magnets, ideal for high-throughput machines and assembly lines
- Synchronous and asynchronous bi-directional transfer.
- Compatible with standard TSplus modules for creating a complete loop or as a stand-alone section.
- Precise motion profile and stopping control with acceleration up to 30 m/s² and speed up to 5 m/s.
- Positioning repeatability down to ±20 μm.
Battery Pack Assembly
Process-reliable smart conveyor and positioning systems are crucial for battery module assembly. The Battery Customer Innovation Center showcases Bosch Rexroth’s advanced automation technology, including linear modules and Cartesian systems for precise positioning, as well as advanced resistance welding systems.
Linear Modules and Cartesian Systems:
- Pre-configured components designed to reduce engineering, assembly, and start-up time.
- The LinSelect system configurator swiftly integrates with the latest BOM and CAD models
- High system dynamics and stiffness, with repeatability to ±50 μm.
- Compatible with dry-room environments.
Resistance Welding Systems
The Battery CIC includes a resistance welding lab featuring Bosch Rexroth’s modular system with advanced welding controls, AC or MFDC inverters, and control software, along with interfaces for all popular fieldbuses. These systems are designed to enhance the overall system and process reliability, with Weld Spot Analytics software assisting welding engineers in making better, more assured decisions. Together with adaptive control, these features ensure high-quality welds and minimize inefficiencies in high-production environments.
End-of-Line Testing
Battery packs are complex devices that must meet stringent safety standards. Bosch Rexroth’s end-of-line (EOL) test systems at the Battery CIC feature scalable IndraDrive ML and fastPLC system ILC, offering:
- Efficient utilization of shared hardware for power supply, drive inverter, and DC/DC converter
- Efficient line regeneration and low harmonics.
- High power handling (up to 1000V DC and 500kW).
- Achieving the lowest ripple of DC voltage and current
- Compact footprint, cabinet size, and system weight.
- Future-proof open connectivity with protocols such as PROFINET, EtherCAT, Sercos, Ethernet/IP, Modbus TCP, OPC-UA, LabView, Simulink, and Java.
Bosch Rexroth’s innovative automation technologies at the Michigan CIC demonstrate their commitment to advancing battery system production, ensuring process reliability, and enhancing overall efficiency and performance.
