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Production of Lithium-Ion Batteries
Production of lithium-ion batteries – Precision and reproducible deep drawing of composite foils
Jonas & Redmann developed a precision, flexible R&D system for the reproducible deep drawing of composite foils, e.g. aluminium composite foils. The (stand-alone) laboratory machine offers an array of process modes and optional expansions.
Benefits at a glance:
After a short introduction, Jonas & Redmann laboratory systems can be commissioned in just a few easy steps and are easy to operate.
All Jonas & Redmann laboratory systems are low-maintenance and pre-calibrated.
High-precision system components produce reproducible test results.
System options enable the evaluation of a wide range of process parameters as a basis for scaling up or optimising existing processes, for example.
Thanks to its compact, modular design equipped with rollers, the system is easy to handle in laboratory environments.
In contrast to hard case battery cells, foil cells (also coffee bag or pouch cells) made of aluminium composite foils offer advantages when it comes to gravimetric energy density as well as a high degree of battery format flexibility thanks to the relatively easy processability of the housing materials.
Depending on the specification, the pouch cell must be deep-drawed into varying shapes. The quality of the deep drawing process has a direct impact on the parameters life cycle (at the cell and system level) and safety. To implement an industrialised, stable and high-quality deep drawing process, the largely unknown behaviour of multiple layer composite foils in deep drawing processes must be evaluated in prototype and material testing and examinations on the optimum parameter settings of the forces applied to the blank.
Jonas & Redmann offers a semi-automatic, modular laboratory system for these tasks. The new development is suitable for universities and research institutes as well as companies for evaluating production and process parameters.
Flexible and scalable
The easy-to-use, scalable laboratory system offers a wide range of functions. Optional expansions offer flexible options for using the machine in product development.
The control has a open design, thus enabling customer-specific integration and an expansion of the functions and sensors. The depth (distance), deep drawing force (forming force), deep drawing speed (forming speed), blank-holder force and holding time parameters are freely programmable.
The drawing punch, draw ring and blank holding device can be optionally set to a defined temperature (room temperature up to 120°C) by the integrated heating elements.
The optional punching tool (hole punch) makes it possible to index deep-drawed half shells. Two half shells can be aligned using these indexing holes when assembling battery cells.
Similar to the drawing punch, a servo-electric spindle press can be mounted instead of a pneumatic drive. This increases precision and allows for additional deep drawing operating modes.
In addition, the standard system repeatability of <1% of full scale (nominal load) can be optionally reduced to <0.3% of full scale.
User friendly and low-maintenance
The compact system is operated using a mobile control panel with a touchscreen, which makes it easy to operate and display operating and fault messages. The process parameters are entered and recipes are created by an external PC or the operating personnel. The control writes the various machine process parameters cyclically (including the time stamp) to a single data file. The interval for each parameter – within the limit defined by the system – is freely programmable via the HMI.
Innovation by cooperation
Jonas & Redmann considers the entire process chain of broad basic research and applied research, including the development of prototypes in the system context, and cooperates with scientific partners particularly in the field of battery production. By working with research institutes such as the “Battery LabFactory Braunschweig” (BLB), it is possible to efficiently develop products and production technologies with equal efficiency. Alexander Tornow, graduate engineer at the Institute of Machine Tools and Production Technology (IWF) at the Technische Universität Braunschweig stresses in this context: “The laboratory deep drawing system from Jonas & Redmann, which is used in the Battery LabFactory, is an excellent example of the transfer of scientific knowledge to optimize research facilities.”
Contact at TU Braunschweig
Dipl.-Ing. Alexander Tornow
Institute of Machine Tools and Production Technology (IWF)
a.tornow@tu-braunschweig.de
We are specialists in the field of production process technologies and are able to make the automation of almost any process reality. These include processes which have either not yet been automated or previously considered as non-automatable. Let us share our expertise so you can profit from our extensive process know-how from numerous projects.
In automated assembly, both the joining and connecting of the functioning units play a key role. We integrate a wide range of connection technologies in our comprehensive solution for the assembly of electronic and automotive components.
We have engineering expertise for the processing of numerous high-tech materials. Our automation solutions come equipped with a high level of precision and quality to ensure your complex product is produced according to specifications.
Jonas & Redmann are specialists in the conception and production of highly intelligent assembly solutions as well as customized handling technology. We have almost 30 years of experience on these fields.
We offer reliable in-line inspection technology and in-process analysis software for consistent quality management in ongoing production. We consider all metrologically relevant steps already during the conception phase of a machine or production line.
In the field of industrial material processing, the application areas for lasers are as diverse as the technologies behind them. At Jonas & Redmann, we offer the integration of laser technology in automation technology – and paired with sound process competence in numerous laser applications.
Specific development, having taken place in the field of screen printing since 2009, and combined with our expertise in the processing and handling of hard-brittle materials, has led to pioneering metallization systems and helped to equip them with competitive and unique selling point features. We would be happy to incorporate our expertise in industrial screen printing into your project.
We develop individual software as either an integral part of your machines or as a complimentary application. You benefit from our experience with numerous control and visualization systems.
Jonas & Redmann have extensive expertise in the automation of complex and multi-layered production processes.
We are particularly specialized in the development of technologies for production processes, which have either not yet been automated or were previously considered as non-automatable. Let us share our expertise so you can profit from our extensive process know-how from numerous projects in the high-tech sectors: photovoltaics, energy storage, medical engineering and assembly automation. With our extensive expertise, we offer our customers tried and tested processes and efficient system solutions for demanding applications.
Development of new production technologies and the necessary machines
Standardized platforms for automation, measuring technology and process technologies
Laboratory equipment systems, individual plant systems, integrated production lines
In automated assembly, the joining and connecting of the functioning units play a key role.
We integrate a wide range of connection technologies in our comprehensive solution for the assembly of electronic and automotive components.
Joining technology
Screw technology
Press-fit technology | precision pressing
Riveting technology
Soldering for selective soldering
Heat sealing
Welding technology
Adhesive and dosing technology
In the production of high-tech products, sensitive or pliable materials pose high demands on processing and marking processes.
From hard-brittle silicon, to pliable ultrathin foils, through to fine hollow fibers – our engineering expertise makes it possible to process numerous high-tech materials. Our automation solutions come equipped with a high level of precision and quality to ensure your complex product is produced according to specifications.
Filling / Dosing of solids and fluids
Precision dispensing of pastes and adhesives
Surface coating with pasty media
Using die cutter for the shaping of foil blanks
Z-folding of separators in accumulator production
Reshaping of hoses/tubes
Reshaping | Deep drawing of composite films
Bundling and cutting of hollow fibers
Laser marking
Pad and ink-jet printing
Labelling
Jonas & Redmann are specialists in the conception and production of highly intelligent assembly solutions as well as customized handling technology.
We offer scalable automated and semi-automated assembly and handling systems, for which various elements can be easily reconfigured. By making sure our components are easily convertible, we ensure your flexibility and enable the production of various product types. The integration of additional modules with new functionalities into existing lines can be easily implemented.
Assembly of very small parts with high cycle times
Precision and micro assembly machines
Sorting technology for bulk materials
Pick & Place module | Assembly-handling modules
Robotics (all kinematics)
Palletization units
Stacking units
Dosing units
Material feed
Transfer systems
Portal handling
Special grippers for flexible materials
Special grippers for hard/brittle and ultra-thin materials
Transport and storage devices for sensitive products/customized
Modular grippers for easy conversion when changing variants
Workpiece carrier (WT) transfer systems
AGV – Automated Guide Vehicles
Overhead transport systems
We offer reliable in-line inspection technology and in-process analysis software for consistent quality management in ongoing production. We consider all metrologically relevant steps already during the conception phase of a machine or production line. On request, when finished, the complete solution includes comprehensive quality inspection and evaluation of each measuring cell as well as all inspected objects.
Material receiving inspection
Continuous testing and monitoring during production with integrated NIO parts removal system
End-of-line Test
Robot-vision systems
Surface inspection
Measurement of layer thickness
Precision weighing
Assembly and completeness check
Code identification
Inline measurement
We offer the integration of laser technology in automation technology paired with sound process competence in numerous laser applications.
Due to the fact that we have our own laser laboratory and are in close cooperation with competence centers in the fields of laser sources and optics, we are able to keep up with rapid technological development and the implementation of customer-specific laser processing systems.
Structuring of Solar Cells
Automated tab welding in the production of lithium-based battery cells
Cutting | Separation of solar cells
Stripping | Decoating e.g. of enameled copper wire in stator production
Marking
Jonas & Redmann are leading producers of fully-automated screen printing systems for the front and backside metallization of crystalline silicon solar cells.
Specific development, having taken place in the field of screen printing since 2009, and combined with our expertise in the processing and handling of hard-brittle materials, has led to pioneering metallization systems and helped to equip them with competitive and unique selling point features. We would be happy to incorporate our expertise in industrial screen printing into your project.
Highest possible level of accuracy in object orientation and screen printing
Soft-Print Technology through low-contact transport and processing strategies
Unique screen lift kinematics for high screen life
Innovative pressure deposit coating
Multi-layer printing processes with the highest level of precision possible
Automation software is essential to ensure a high level of both functionality and efficiency. A core competence of Jonas & Redmann is the development of individual software for technically complex machines and systems.
We develop individual software as either an integral part of your machines or as a complimentary application. You benefit from our experience with numerous control and visualization systems (Siemens, Beckhoff, Allen Bradley, customized).
High-level language programming
Manufacturing Execution System (MES) interfaces
System integration of measurement technology | Process technology
Programming of industrial robots
Performance increase through software | Diagnosis and remote access
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