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With the increasing demand for electric vehicles, the production of high-quality batteries is also becoming more and more important. With more than 15 years of experience, we have established ourselves as a competent partner in the field of battery production. With our technology, we are able to optimize the production process of battery components and offer holistic solutions for efficient battery production.
With over 15 years of experience in battery manufacturing, we have established ourselves as experts in battery assembly solutions, especially module and pack. In our portfolio you will find solutions for all common cell types (cylindrical, prismatic, and pouch cells). Our level of automation is adjustable, offering both semi-automated and completely automated solutions to meet the specific needs of our clients. We pride ourselves on our digital production engineering, utilizing a model-based digital toolchain to optimize efficiency and accuracy. Our competence lies in our process technology, including advanced joining techniques, machine vision systems, and comprehensive testing capabilities. Additionally, we provide simultaneous engineering support, assisting with line dimensioning and process application to ensure seamless integration into our clients' operations.
We provide comprehensive battery cell testing solutions, covering essential parameters such as current, voltage, temperature, and State of Charge (SOC). Our services include precise identification of key battery cell metrics, including Open Circuit Voltage (OCV), AC Impedance (ACIR), DC Impedance (DCIR), and SOC, ensuring accurate performance monitoring at every stage.
We provide high-speed, smart handling systems and scalable machine concepts for processing various cell packages (blisters, cartons, etc.) and cell types. Our solutions are designed for everything from small-scale sample production to fully automated manufacturing lines, with seamless on-the-fly cell type changes. Our customizable robot-based handling concepts ensure efficient process management and precise handling. With extensive expertise in robotics, vision systems, joining, and testing, we deliver high output rates and optimized machine footprints. Additionally, Simultaneous Engineering and Material Flow Simulation help drive process improvements, boosting productivity across the entire production flow.
We provide advanced cell cleaning solutions to prepare surfaces for gluing and laser welding processes. Our technology is versatile, addressing a wide range of cleaning needs — from contamination removal to surface texturing. We tailor cleaning parameters to your specific requirements, offering solutions that include compressed air, plasma treatment, and laser cleaning. Additionally, we design and manufacture custom suction devices in-house to optimize cleaning efficiency.
We enable the dispensing of TIM, sealant and encapsulant materials with precision down to 0.1 mg, dynamic positioning repeatability of +/-0.3 mm and a linear driven axis of up to 1.5 m/s. Our solutions include height measurement and post-processing for quality assurance and allow for non-disruptive material changes, as well as SPC drawer solutions to minimize machine downtime. Our systems are flexible and allow full or partial integration of systems from different manufacturers into one control system.
We offer laser welding solutions for all types of cell connectors, flexible conductors and other components, including aluminum and plastic housings. Our technology can process all materials from aluminum and copper to plastics in all thicknesses from 20 µm to several millimeters. All types of laser sources, from pulsed to multi-kW cw, and all types of processing optics can be used. Our innovative process control allows for the highest welding speeds, resulting in the highest quality welds.
Our welding technology provides robust, field-proven solutions for welding a wide range of materials, including difficult-to-weld materials. Our energy input is low distortion, low spatter and enables high process speeds. This makes our technology ideal for welding cell connectors, printed circuit boards and flexible foils with online process monitoring for quality control. Our solutions offer high flexibility with a variety of inverters and welding heads/tongs that can be optimally adapted to the welding application.
We offer solutions for detecting very small leaks along the weld seam at high processing speeds and for cycle time optimized loading and unloading of the battery. We achieve process speeds of 15 cm/s and can detect the smallest leaks in a 10,000 liter test chamber at a rate of 1E-5 mbar*l/s. Our technology provides good accessibility while protecting against deformation. For process optimization, we offer full simulation of robot movements in advance, as well as specific test procedures in the laboratory.
We offer high-quality optical inspection machines and advanced measurement systems for precise quality control of cell contacting systems, including cells, active joining, and weld seam monitoring. Our solutions provide inline measurement of battery and cell contacting systems, optimized for on-the-fly laser welding. With a fully equipped machine vision lab, we develop innovative applications to meet your specific needs.
Bosch Battery Texture Traceability (BATT) is a non-contact battery material traceability technology based on vision systems and deep learning. It offers advantages such as non-destructive inspection, high compatibility, easy maintenance, low cost, and high integration, making it suitable for both continuous production and one piece flow manufacturing scenarios. Customizable for deployment across front, middle, and back-end cell manufacturing processes, BATT can be embedded into production lines per customer requirements, binding key process data such as coating density and rolling thickness. The precisely traced data enables big-data quality analytics or closed-loop process control, enhancing full lifecycle product traceability.
From coating to winding/stacking, BATT utilizes vision imaging and deep learning to record unique surface texture characteristics of electrode sheets. It provides a high-resolution (meter- to centimeter-level), non-contact, high-accuracy traceability system across the entire production process.
Applications
Smart Battery Formation combines highly efficient power electronics with intelligent energy management to significantly lower operating costs of the battery cell formation process. Its modular design optimizes space efficiency and offers flexibility for various cell dimensions and workpiece carriers. This allows for seamless integration into your cell finishing processes in both pilot lines and gigafactories, enhancing overall productivity and adaptability.
Our Smart Formation Chamber is specifically designed for the formation of prismatic and cylindrical battery cells, offering optimized floor loading and space efficiency through a flexible modular concept. It ensures high technical availability with easy maintenance and quick repairs — under 5 minutes — thanks to replaceable contacting modules.