Customized turnkey solutions for battery pack production with Schaeffler Special Machinery
At Schaeffler Special Machinery, we design customized solutions and deliver technological excellence in battery pack production. We successfully execute complex and extensive battery system projects in a simultaneous engineering environment by leveraging the strengths of our global network and modern approaches, such as virtual commissioning, and innovative technologies.
Process sequence for the assembly and testing of battery packs
Our turnkey solutions for battery packs integrate all the processes required for efficient and reliable battery production. This includes the precise insertion and fastening of the battery modules in the battery housing, followed by electrical and thermal integration. We ensure that the housing is securely sealed and carry out a leak test to guarantee quality and safety. The next steps involve charging and flashing the battery pack, followed by a comprehensive end-of-line test with load and function tests as well as insulation tests.
Process highlights of our turnkey solution:
- Asynchronous workpiece transfer systems - freely navigating or rail-bound
- Precise dosing, application of gap fillers and thermal interface layers
- Automatic joining of battery modules with tolerance compensation
- Laser structuring and plasma activation of surfaces for adhesive pre-treatment
- Application of structural adhesives and liquid sealants
- Leak tests with helium or air
- Filling and venting the cooling circuit
- Optical testing of adhesive beads, surfaces or joining geometries
- End-of-line testing with automatic plug contacting and performance test
Progress in plastic welding for battery modules and packs
Our technology experts have developed a new plastic welding system. With our A2A plastic welding process (short for "absorbent to absorbent"), conventional plastic welding processes can be replaced, eliminating the need for expensive, laser-transparent materials. Additionally, we enable the welding of different plastics belonging to the same chemical group.
Along with the new, unrestricted design freedom, the welding process's energy consumption is reduced, its speed is increased, and the cost of materials is significantly reduced. We see applications for cell holders, module boxes, battery module housings, battery management systems, and plug and cable connections.
Benefits of working with Special Machinery for the production of battery systems
Schaeffler Special Machinery offers the integration of customer-specific processes into sophisticated, turnkey machine solutions. Our machines benefit from our decades of experience within the Schaeffler Group, which gives us a deep insight into production processes. With our own testing technologies, advanced automation, vision systems as well as high-speed handling and robotics, we implement customer-specific requirements precisely and accompany you from the development of the first prototypes through to series production.
From start-of-line to end-of-line – our comprehensive and smart test systems for battery packs are characterized by a minimal footprint and maximum efficiency. We offer a wide range of tests, from helium leak testing, optical tests, charging and discharging performance tests, potential equalization, insulation resistance and much more.
Our proven ramp-up performance ensures that your production systems are commissioned quickly and reliably. Our modular and scalable concepts for battery systems grow in line with actual requirements. Thanks to our broad in-house expertise, we offer our customers integrated machine solutions as a one-stop store, all from a single source.
Thanks to our global network, we offer comprehensive service availability with short response times, local implementation with high standards worldwide and cost benefits through decentralized production structures. In this way, we combine economic efficiency with technical excellence and ensure that your specific requirements are met precisely and reliably worldwide.
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In addition to conventional architectures, we also offer turnkey assembly systems for innovative concepts such as cell-to-pack, cell-to-chassis and cell-to-vehicle, which can be flexibly adapted to your target systems and specific requirements.
