Automation in EV production

Magnetic gripper technology revolutionizes battery handling

With the rise of electromobility, the demand for innovative charging solutions and electric vehicles is growing. Intelligent automation solutions for the production of battery cells, packs and modules are in demand.

With the upswing in electromobility, the demand for innovative charging solutions and electric vehicles (EV) is also growing.

While manufacturers are no longer investing in the development of new combustion engines, the production of EVs is growing rapidly. This development is presenting car manufacturers and suppliers with new challenges, which they are meeting with intelligent and flexible automation solutions from Zimmer Group.

From prototypes to mass production: the challenge of scalability

Manufacturers of electric vehicles are currently looking for innovative and automated solutions to make their production processes more efficient, reliable and productive. In battery production in particular, the comparatively low but increasing production volumes pose a major challenge. Automation solutions must therefore be flexible in order to scale up quickly from prototypes to series production.

Developers and engineers are often under time pressure, as product development and automation have to run in parallel. Some projects even require basic research for new technologies. This requires a high degree of flexibility in the design of automation solutions and in the thinking of the engineers involved.

As an automation specialist, customer requirements vary greatly - from machine builders to robot system integrators and original equipment manufacturers (OEMs). This is why every customer receives intensive and personal support from the initial inquiry through to implementation. Thanks to decades of experience, THE KNOW-HOW FACTORY has established itself as an important development partner for renowned automotive manufacturers with its knowledge and in-house production depth.

The evolution of automation: from the combustion engine to e-mobility

The switch to electric drives was already noticeable for Zimmer Group in 2014. As an automation specialist, the company has built up an extensive portfolio in the development and production of handling technology and system solutions for the automotive industry over many years. Cylinder heads, engine blocks and crankshafts used to characterize the gripper manufacturer's business. Today, battery cells, modules and electric motors have been added - Zimmer Group supports the entire EV powertrain value chain, from individual components to complete systems.

In order to actively shape the technological shift from the combustion engine to electromobility, the company draws on its more than 30 years of experience with end-of-arm tooling (EOAT), which is used in the assembly of powertrains and the feeding of production lines in the automotive industry. As a result, several modular solutions for the construction of electric vehicles and batteries have been developed in a short space of time.

The company focuses on close cooperation with its customers. Zimmer Group sees itself as a research and development partner for automotive manufacturers and offers solutions for the operation of production lines, handling systems and tools for the manufacture of battery cells, packs and modules. The entire battery production value chain - from cell production to assembly and handling of the housing - can be covered with automated solutions. In addition, Zimmer Group offers specific solutions along the value chain for rotors, stators, contact rings, gear wheels and various add-on parts.

Magnetic grippers for round cells: from standard to system

Individual components, special handling, industry standards and individual requirements - with its broad portfolio, Zimmer Group meets almost every customer requirement in the field of e-mobility. The company draws on decades of expertise and technologies in the mobility sector and implements system solutions based on the modular principle. This is evident, for example, in a magnetic gripping system for round battery cells:

Gripping round cells in the production of electric vehicles poses a particular challenge. These must be gathered in the process, i.e. brought as close together as possible, in order to make optimum use of the limited installation space in the vehicle. Zimmer Group has solved this challenge with a scalable gripper system based on a standard magnetic gripper.

The compact design was combined with a holding force of 50N, so that the round cells are held securely even at high accelerations and emergency stops. The low residual holding force of less than 1N with deactivated magnets not only enables reliable depositing, but also meets the requirements for technical cleanliness.

The gripper can be combined with both piston position sensing and battery presence detection, and axis compensators are available which, in conjunction with centering plates, compensate for cell misalignments that occur in the various manufacturing processes. In addition to this combination, the HM1046 is the only magnetic gripper on the market that also offers the option of vacuum-assisted gripping. This combination of two redundant gripping principles generates holding forces of up to 200N and increases process reliability to a maximum.

Know-how and network: the strengths of the Zimmer Group

In order to meet individual customer requirements and to be able to react at short notice, Zimmer Group has developed a high level of vertical integration. In the Systems Technology division alone, the company has its own machine park with around 15 machining centers. A further 300 machines are available in other areas of the company, which can be called upon at peak times. The Zimmer Group also has expertise in special processes such as 3D printing, plastics processing and metal injection molding (MIM), which can also be implemented by Zimmer Group.

In addition to its in-house expertise, Zimmer Group has developed a strong partner network that enables fast and effective machining, sheet metal processing and welding technology. This enables the automation specialist to offer a wide range of services and comprehensively meet the requirements of its customers. The global positioning of Zimmer Group with 125 sales offices worldwide enables the KNOW-HOW FACTORY to offer comprehensive customer service locally and to drive automation in companies internationally.

Equipped for the future: Standardization meets innovation

Thanks to decades of close cooperation with automotive manufacturers, Zimmer Group was able to foresee the changes in the industry at an early stage. Now the standardization of automation solutions is in demand. This is already the case in the production of combustion engines thanks to many years of experience. And the e-mobility portfolio is also growing: since 2014, Zimmer Group has built up a pool of scalable system solutions. System installations are developed and delivered faster and more cost-effectively. The KNOW-HOW FACTORY, with its in-house developments, high vertical range of manufacture and strong network of automotive industry and partner companies, has set itself the task of driving forward the automation of processes in e-mobility.

Find out more here: E-mobility - Zimmer Group ( zimmer-group.com )

Author information: Johanna Pompe , Editorial Office & Content Editor, Zimmer Group

This post originally appeared here .