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KUKA Robot Guide
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Automation in battery production

From the individual battery cell to the assembly of complete battery packs: With many years of expertise, KUKA covers the entire value chain in battery production systems and supplies corresponding automation solutions.

Efficient, fast, safe and environmentally friendly: Automation optimizes battery production

Demand for lithium-ion batteries is booming. From smartphones and tablets to e-cars: nothing runs without batteries. Accordingly, the required quantities in battery production are increasing rapidly. The solution lies in automation. This is because the manufacture of batteries is technically demanding and requires high safety standards. The necessary fast cycle times can best be achieved by means of automation. In addition to robotics and know-how, KUKA also supplies customer-specific overall concepts for each individual process step in battery production.

KUKA is your strong partner for battery production at every point in the process chain

Sustainability is becoming more important in battery production, and KUKA is taking up the challenge. We provide support with suitable robot models and customer-specific automation concepts.

Are you looking for innovative process technology for the manufacture of high quality lithium-ion batteries?

We are there for you on site with competent contacts worldwide. We support you with concepts, production methods or trial equipment up to production support during the start-up phase and service after project handover.
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From planning to implementation and recycling: KUKA is contributing to the successful technological and economical implementation of innovations in the field of e-mobility

We stand for long-lasting innovations: from individual robots to complete production lines. Our expertise is in the planning, design and commissioning of turnkey production lines for battery modules and battery packs. The portfolio of products and services covers the wide range of production processes from precision laser machining and welding to the associated measuring and inspection systems. KUKA offers automation solutions for the entire value chain of battery production. Sustainable process technologies play an important role here. Cost-effective and environmentally friendly battery production is no longer conceivable without considering the planning and preparation of re-use or recycling of batteries before production.

Everything from a single source for your battery production

Broad robotics portfolio

  • Robots with a payload capacity of up to 1300 kg
  • Various kinematic systems, integrated controller architecture: DELTA robots, SCARA robots, cobots, six-axis industrial robots
  • Robots for cleanrooms and dry rooms, ESD-protected as standard
  • AMR logistics solutions
  • Linear unit for up to 4 robots, extension of the working range up to 31 m
  • Wide-ranging portfolio of ready-made application software

Long-standing expert in systems engineering

Flexible automation concepts

  • Scalable modular solutions
  • Acquisition of real-time data and control of processes thanks to IIoT technology from KUKA
  • 6-axis robots allow payload upgrades in the field for adaptation to new tasks
  • In the event of a product change, it is sufficient to adapt the software instead of exchanging the hardware
  • Effective planning tools such as 3D simulation or offline programming
  • Digital twin of the system enables cycle time optimization, predictive servicing and more

Service life cycle management

  • Feasibility studies, prototype construction
  • Engineering, simulation and programming services
  • Start-up
  • 24/7 professional support
  • Spare parts supply within 24 hours
  • Resources for implementing large-scale projects
  • KUKA College: Robot training courses for every requirement, in standardized and certified training rooms around the globe and also on site at the customer

Everything you need for intelligent automation

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Robots
Software
KUKA Services
KUKA College

Für jeden Kunden das maßgeschneiderte Konzept

Um eine maximale Expertise zu gewährleisten, stellen wir für jedes Projekt ein Team aus Spezialisten verschiedener Bereichen zusammen. Mit unseren effektiven Programmmodulen wie 3D-Simulation oder Offline-Programmierung lässt sich Ihre Batterie-Fertigung verlässlich planen, optimieren und im Voraus berechnen ohne die laufende Fertigung zu unterbrechen.

Wir erarbeiten holistische Lösungen und reagieren flexibel auf den dynamischen Markt:

ElringKlinger AG
Highly automated module production line

The modular battery module production line extends from the inspection and assembly of the battery cells to the electrical linking and measurement of the battery modules and even to the automated electrical and mechanical final testing of the battery modules.

Webasto Group
State-of-the-art production for battery systems

In the multi-product line for the production of various battery types, all production processes are efficiently interlinked. The result is impressive: A complete battery pack is finished every 15 minutes.

Liebherr-Verzahntechnik GmbH

Secure assembly of HV batteries

The automated linking of modules is achieved using non-rigid high-voltage module connectors, with multiple compact machines operating synchronously and in parallel in real time. Integrated cameras ensure utmost precision.

OEM and Tier 1 company
Production line for e-mobility battery carriers

The automated battery carrier production line includes friction stir welding, component handling, deburring and integration into upstream and downstream processes. Finally, the robot-based FSW application module is used.

The right solution for every step of the value chain

Battery cell production

In the production of lithium-ion battery cells, special high-precision machines are used for individual production steps. KUKA robots can take over certain key processes such as stacking, loading and unloading, or formation and aging of cells. Industrial robots that are certified for cleanroom operation and suitable for operation in dry rooms are used for this.

KUKA robots in the production of lithium-ion battery cells or pouch cells
KUKA robots in the production of lithium-ion battery cells or pouch cells

Battery module assembly

In this process step, lithium-ion cells are assembled into modules and connected in series or in parallel. KUKA supplies the turnkey system and keeps an eye on everything: In addition to optimal handling and welding solutions, adhesive bonding, pressing and electrical and thermal contacting are relevant key processes here. KUKA offers the solution expertise required in this field to plan and implement the systems flexibly and efficiently. Module lines are possible for cylindrical as well as prismatic and pouch battery cells.
We rely on advanced process technologies for the manufacture of lithium-ion batteries in order to achieve a continuous increase in their efficiency, performance and sustainability, thereby driving electromobility.

Assembly of battery packs

The battery pack for electric cars, for example, consists of battery modules and other electrical, mechanical and thermal components. KUKA provides support in the form of flexible and modular systems that have different dimensions depending on the required performance data. In general, cast aluminum structures are often required in pack assembly. KUKA has expert knowledge and suitable technology concepts for this. Furthermore, our friction stir welding (FSW) technology is the ideal process for sealing cooling circuits in aluminum structures.
We equip our customers worldwide with sustainable concepts for the electromobility of the future

Inspection systems for module and pack lines

High-performance batteries such as lithium-ion batteries must meet strict safety requirements and maximum quality standards. KUKA integrates a large number of inspection stations into the planning of the system. Each individual component is repeatedly tested during the battery production process, culminating in the end-of-line test of the battery. In addition to the leak test, the battery systems undergo further extensive electrical tests. Additionally, the electrical properties of the battery are tested, necessitating the corresponding high-capacity charging and discharging equipment. Strategies for reworking in the event of a fault are always taken into account in our systems.
Fully automatic end-of-line test stand

Cell-to-Pack technology

“Cell-to-Pack” (CTP) technology, also called “Module-to-Body” or “Cell-to-Body”, is a special process in the production of batteries for electric cars and other battery systems. The individual battery cells are assembled directly into complete packs and integrated into the end product. In this case, various fastening materials can be dispensed with and an increased energy density of the packs is possible. On the production and assembly side, KUKA provides support in the form of innovative developments within the production system in order to ensure that the respective battery designs are optimally inserted into the vehicle body. The broad technology portfolio enables, for example, the rotation of vehicle bodies so that cells can also be inserted and joined in positions that are difficult to access. KUKA already researches and develops corresponding solutions in the field of CTP, drawing on the experience gained in the manufacture of battery cells and the assembly of battery packs in electric cars.

Battery recycling

The need to develop cost-effective and sustainable concepts for reuse, recycling and raw material recovery is increasing, particularly in the global production of lithium-ion batteries. KUKA is actively involved in research in order to advise its customers on possible concepts for sustainable battery production and supply chain during the planning process. On the one hand, suitable battery designs and the right components can ensure that modules are dismantled without damage in a recycling facility designed and installed by KUKA and fed to a 2nd life cycle and re-use. Various technologies are combined to enable optimized disassembly of the packs. The other objective is to develop a disassembly-friendly design of the batteries together with our customers in order to achieve increased recyclability. Raw materials such as lithium, cobalt, nickel and manganese can thus be recovered more easily.

References: From cells to modules to packs