The aim of the EXINOS2 project is to develop and industrialise the prototype plant concept for optimised stacking in battery cell production.

The development and industrialisation of a new type of production plant for the manufacture of battery cell stacks is the goal of the EXINOS2 joint project (FKZ: 03XP0645A-F). The plant concept, which builds on the results of previous research projects, promises significantly improved efficiency and flexibility in battery cell production through the use of innovative technologies. In the joint project, researchers from the wbk Institute for Production Technology at the Karlsruhe Institute of Technology (KIT), the Fraunhofer FFB Battery Cell Research Production Facility and the industrial partners acp systems AG, BST GmbH, J. Schmalz GmbH and Siemens AG are working on the further development of the prototype plant concept. The Federal Ministry of Education and Research (BMBF) is funding the project with 3.64 million euros.

The system concept, which has already been built as a prototype, offers optimisation potential with regard to both of these challenges. By creating a composite of the separator and the electrode sheets before the actual stacking process, a continuous and therefore overall faster process control can be achieved. The system technology itself is designed to be format-flexible, so that new cell formats can be switched to within a short time using software. This is achieved primarily by the flexibly adjustable handling systems, which are also used to cut the individual electrode sheets.

The efficiency and flexibility of battery production in Germany, which is expected to make a decisive contribution to the energy transition in the future, can thus be significantly improved. This in turn opens up great opportunities to strengthen economic power and technological innovation and to promote the expansion of electromobility.

Within the three-year project, all sub-processes of the prototype system concept are to be further developed and tested to ensure series production suitability in accordance with industrial standards. In addition, alternative technologies will be integrated and tested within the system. Digital methods play an important role here. For example, a multi-physical system simulation can help to optimise the position of individual components within the machine. In addition, the developed ‘digital twin’ can accelerate the commissioning of the system and also provide valuable information for the machine operator within the production process. This can also build on previous research results from the battery competence clusters ProZell and InZePro, which are also funded by the BMBF.

Project partners and roles in the project

acp systems AG (project coordination)

Dr. Frank Stubhan

Albring 18, 78658 Zimmern ob Rottweil

+49 741 175299 30

[email protected]

acp systems AG acts as the manufacturer of the focused target system in the project.

BST GmbH

Klaus Hamacher

Remusweg 1, 33729 Bielefeld

+49 521 400 70 691

[email protected]

In the project, BST GmbH is supplying a high-precision system solution for web guiding and optical electrode inspection for optimal stacking accuracy of the electrode sheets.

Schmalz GmbH

Dr. Harald Kuolt

Johannes-Schmalz-Straße 1, 72293 Glatten

+49 7443 2403 462

[email protected]

Schmalz GmbH is involved in the development of suitable vacuum gripping systems within the project.

Siemens AG

Daniel Leinmüller

Otto-Hahn-Ring 6, 81739 München

+49 1744929552

[email protected]

Siemens AG is supporting the project on the hardware side with regard to control and drive components and on the software side in the digitalisation of the target system.

Karlsruher Institut für Technologie (KIT)

wbk Institut für Produktionstechnik

Prof. Dr.-Ing. Jürgen Fleischer

Institutsleiter wbk Institut für Produktionstechnik

Kaiserstraße 12, 76131 Karlsruhe

+49 721 608 44009

[email protected]

The wbk Institute of Production Engineering at the Karlsruhe Institute of Technology is dedicated to the project of enabling immature sub-processes and the development of the digital twin.

Fraunhofer-Einrichtung Forschungsfertigung Batteriezelle FFB

Dr.-Ing. Jonathan Krauß

Bergiusstraße 8, 48165 Münster

+49 2418904 475

[email protected]

In the EXINOS2 project, FFB provides the appropriate framework conditions for plant design and integration into an industrial, physical and digital infrastructure in the context of the innovation modules.

Project funding

Funded by the German Federal Ministry of Education and Research (BMBF)