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The new production development center for batteries is an AVL competence center, which provides the automotive industry with optimal support as it goes through the current change to e-mobility. As well as the functional development of new high-voltage batteries for electric vehicles, the main focus is on the development, implementation and validation of new, highly efficient production processes. Using various simulation tools, these processes can be flexibly adapted to meet new demands and implemented in large-scale production at customers at an early stage. This allows module prototype, pack prototype and small batch production under large-scale conditions.
The whole process, from commissioning to start of production at the customer’s facility, is reduced significantly by the experts and methodologies applied by the Battery Innovation Center (BIC). At the same time, a new level of product quality and process reliability is achieved.
DI Martin Weinzerl
• functional development of new high-voltage batteries for electric vehicles
• development, implementation and validation of new, highly efficient production processes for batteries
• module prototype, pack prototype and small batch production under large-scale conditions
Methoden & Expertise zur Forschungsinfrastruktur
The BIC is designed for a wide range of battery developments. All the current core processes of module and pack production can be mapped at the various stations, some of which are fully automated. Regardless of cell type, target voltage and integration level, it will be possible to reproduce all the steps involved in module construction and, in the future, pack construction. Furthermore, the industrial robots in the BIC enable AVL to meet requirements in the areas of Cell-to-Body and Module-to-Chassis, which are increasingly important for automobile manufacturers.
The improvement of production processes is accompanied by advanced Virtual Reality (VR) methods. Augmented Reality (AR) is increasingly used in the field of assembly processes. This makes it possible to develop products parallel to the industrialization of batteries to a degree previously unattained. This, in turn, reduces the times-to-market.
Other highlights of the Battery Innovation Center include the validation of manufacturing technologies in real large-scale production conditions. The production processes designed can be tested thoroughly in real conditions in the pilot line. This makes it possible to industrially process all the cell types currently available on the market, with sizes right up to Cell-to-Pack dimensions. Furthermore, batteries – ranging from individual A-sample production to batches of several hundred batteries – can also be manufactured in the BIC, whilst comprehensively monitoring defined quality characteristics.
Strengthening the regional automotive battery cluster with AVL partners Rosendahl Nextrom and Varta Micro Innovation.
AVL is also a member of the IPCEI EUBatIn. Here we establish new cooperations with partners in and outside of Austria for further development in the view of quality increase, reduction of energy consumption in production and speeding up development time for customers.