Battery module assembly: cell format-compatible and scalable

Customized turnkey systems for the assembly and testing of battery modules

Schaeffler Special Machinery offers customized assembly and production solutions for battery modules, whether for prismatic or cylindrical battery cells. We develop and realize turnkey systems that are tailored to the specific standards and individual requirements of our customers. These systems integrate all essential processes to ensure a smooth and efficient production flow.

Battery module assembly: cell format-compatible and scalable

Our production concept for battery modules allows for the production of modules of different sizes and quantities. Adapting the output capacity of our systems to actual requirements optimizes investment costs

Integrated processes in our turnkey systems for battery systems

The following processes, for example, are integrated into our system:

Cell isolation and pre-treatment
Laser and plasma surface treatment
Cell stacking – pre-stressing
Joining the module frame
Positioning and laser welding of the cell contact system
Installation of cooling systems and thermal connection with gapfiller
Electrical, dimensional and camera-based testing processes
End-of-line testing of the battery modules

Innovative solutions for the electrical contacting of battery cells

The electrical contacting of battery cells poses various challenges. For hard-case cells, this is primarily the consistency of the welding depth and quality, and for cylindrical cells it is supplemented by geometric difficulties due to the rounded shoulders of the cells. Due to ever larger battery modules, a high number of welded joints must be realized reliably while maintaining high quality requirements and low heat input. Schaeffler Special Machinery meets these challenges with state-of-the-art technology, including the selection of suitable laser technology, precise control of the welding depth using OCT, integrated cell mapping and efficient quality control. Our station concept includes a sophisticated clamping concept with force monitoring and integrates fast handling as well as continuous cleaning and local extraction for high efficiency and quality.

Innovation for plastic welding of battery module and battery pack components

Our technology experts have developed a new system for plastic welding. With our so-called A2A plastic welding (short for "Absorbent to Absorbent"), conventional plastic welding processes can be replaced, eliminating the need for expensive, laser-transparent materials. In addition, we create the possibility of welding different plastics that belong to the same chemical group.

In addition to the new, unrestricted design freedom, the energy consumption of the welding process is reduced, the speed is increased and the costs for the materials used are significantly reduced. We see fields of application for cell holders and module boxes, battery module housings or battery management systems as well as plug and cable connections, for example.