EV BatteryManufacturing

Driving End to End EV Battery Manufacturing Process

Rockwell Automation’s Expertise on EV Battery Manufacturing

Rockwell Automation understands the commercial and technical requirements for both EV makers and related machine builders to drive integration and create differentiation throughout the entire process.

[ EV Battery Manufacturing Lifecycle ]

• Flexible and scalable on production lines for multiple types of products.

• Easy to change processfor mass-customization.

• Intelligent Conveyor system can increase CPM (Cells Per minutes) productivity up to 25CPM.

• Speed – Reduce cycle time in bottlenecks.

• Increase parts transportation repeatability (50µm).

• Less vibration and dust – Improve quality of Station Jobs.

• Less contamination – less dust and lubrication use.

• Energy saving - smaller layout reduces cost ofclean room operation.

Drive core value of EV battery manufacturers, machine builders and System Integrators to meet the requirements and deliver the project successfully.

Save engineering / maintenance cost to drive higher ROI of CAPEX investment

• Save energy cost by 30% and materials cost by 42%• Single controller to control up to 240 motors

• Reduce commissioning time, reduce downtime (MTTF*, MTTR*) and improve availability.

* MTTF: Mean Time To Failure, MTTR : Mean Time To Repair

FlexibleProduction

HighProductivity

IncreasedQuality

Minimizing Environmental Impact

Our Focus in Automation is ...

Expanding Our Information Solutions

at a glance

Our strategy is bringing The Connected Enterprise to life.We help industrial companies and their people be more productive byintegrating control and information across the enterprise.

FISCAL 2018 SALES

• Design• Configuration• Simulation

• Visualization• Historization• MES (Manufacturing

Execution System)

• Asset management• Network management• Predictive maintenance

• IoT platform• Analytics and Manufacturing

Operations Management• Augmented reality

EMPLOYEES COUNTRIES

$6.7B 23,000 80+

ARCHITECTURE & SOFTWARE

... Where Technology Differentiation and Domain Expertise Matter!

CONTROL PRODUCTS & SOLUTIONS

2 3

PLANNING

• Consulting• Process design• Supplier

engagement

DESIGN

• Specification development

• Automation libraries• Production

engineering

INTEGRATION

• Line integration• Network validation• Startup

engineering

LAUNCH

• Maintenance engineering

• Production reporting

• OEE/KPIs

OPTIMIZATION

• Predictive maintenance

• Production analytics• Production

acceleration

Formation

Electrode Manufacturing Process

Cell Activation Process

Degassing & final sealing

Charge / Discharge testing

Aging

Mixing

Coating

Calandering

Slittering

Roll formation

Separation, Stacking,

Tab welding

Cell filling & sealing

Anode Cathode

Cell Assembly Process

Overall Cost Reduction

Machines & Equipments for EV Battery Production Lines

Enabling Technologies & Portfolio Independent Cart Technology (ICT) overview

Rockwell Automation Linear Synchronous Motors – Independent Cart Technology

Historically, conveyance has incorporated chains, belts, gears and other mechanics. These solutions have limited flexibility, wasted energy and led to excessive maintenance costs. Independent Cart Technology replace these mechanical components with simple, effective software profiles redefining speed and flexibility in automation.

Benefits Independent Cart System Feature

Throughput Fewer mechanical components and linkages creates higher speed.Higher speeds (2.5 m/s) [5.6 mph] combined with fully controlled motion profiles for better carrier positioning.

Flexibility Each moving cart is controlled independently. Flexible mechanical pitch enable the machine to handle multiple package/format sizes at once with full control package.

Constant Carrier Tracking

Integrated track and trace System. Software controlled carts with precise cart positioning eliminate external sensing with complexed tracking solutions.

Increased Uptime

Elimination of mechanical linkages and components allow minimal number of moving parts. It reduces overall downtime, maintenance and energy consumption.

Simplicity Software controlled carts reduce need for components such as sensors, actuators, stops, etc.

ProductivityIncreased

Energy Savingswith Quality Up

Floor LayoutSavings

40% 20% 30%

Integrated Motion Control & Safety MagneMover® LITE

Differentiators

• Easy design and setup• “Erector set” modularity• Integrated merge/diverge• Integrated bearings• Customizable for IP69K and

hygienic design

Key applications

Small-sized battery, General Assembly

INTELLIGENT CONVEYOR SYSTEMS

Differentiators

• Higher thrust and speeds• Flexible layout with variable

motor spacing provides cost efficiencies

• Balance of standard and customer designed features

Key applications

Large -sized battery, Module pack assembly

QuickStick®

QuickStick® HT

iTRAK® Intelligent Track System

Differentiators

• Highest thrust• Capable of moving 5000 kg+• Different size options add

flexibility• Can be hermetically sealed

and operated underwater

Key applications

General EV battery application

Differentiators

• Deterministic closed loop servo performance

• Automatic synchronization with other motion axes

• High dynamic performance and force

Key applications

Small & large-sized battery, General Assembly

We understand machine builder challenges and deliver high-performance motion control systems and integrated safety solutions to help meet your meet your goals.

Simplify machine design while improving overall performance

• Integrated motion with safety (Safe Torque Off)

• Servo drives and motors

• CIP Security in network communication

• Adaptive tuning

MotionControllers

• Logix based scalable multi-disciplined control

• Scalable up to 2 - 100+ axis

• Single software for multiple motion & safety control

• Integrated safety & CIP Security over EtherNet/IP™

Single architecture to control the machine and system

Integrated Safety

• Single platform for safety logic, I/O and component

• Contemporary technology to improve equipment productivity

• Safety consulting to assess, design, and validate safety system

Less unscheduled downtime and more protection for operators

Permanent-Magnet Array

QuickStick Motor

Pallets or Puck

Node Controller

DC PowerSupply

PowerCable

Serial Comm.

Host PLC or PC

Ethernet

Traditional Conveyance vs. LSM (Linear Synchronous Motors)

Customized lengths, not scalable or modular HARDWARE Highly Scalable & Modular

Typically slow. Constant and variable speed when using VFD (Variable Frequency Drives)

THROUGH PUT(Velocity, Acceleration)

Faster acceleration station to station (2.5 m/s) [5.6mph] and 9.8m/s² [1.0g] Multiple modes: Indexing, synchronous, a-synchronous –

Crude simulation, requires precise knowledge of line, each intersection requires station programming (PLC)

TIME TO MARKETFull line simulation: High speed single part or batch transfer. Built in track and trace capabilities

PC based. Pre-determine moves, decision points & stops and starts required

SOFTWAREComprehensive code libraries. Reduction of program complexity, ideal for complex vehicle routing. Anti-collision & automatic queing built-in

Large radius curves. Requires buffer zones to meet similar Magnemotion throughput

FLOOR SPACE20% to 30% reduction in floor space = more production / sq-meter. No need for buffer zones

Conveyor is costantly moving. Motors are fully engaged when power is on. Saves energy when VFD is used

ENERGEY EFFICIENCY

30% to 40% reduction in power consumption - inactive components do not draw power.

100's of moving parts, belts/chains require tightening. Significant spares inventory.

MAINTENANCE & RELIABILITY

No moving parts, higher machine reliability, highest OEE (Overall Equipment Effectiveness) available.

Creates dust and debris.Lubrication is necessary.

CLEANLINESS No particle generation, frictionless, contactless and clean

Traditional Conveyance vs. LSM (Linear Synchronous Motors)

Technology Comparison

4 5

Scalable Analytics by IIoT platforms

Augmented Reality Use Cases : 42% Reduction per Issue

• Reduce dependency on traditional paper manuals, and add ability to update instructions remotely

• Overlay maintenance instructionson how to repair and replace components

▶ 33% reduced downtime

• Operators of machinery can viewan overlay of performance dashboards & manufacturing instructions

• Interactive and situational training that overlays 3D instructions for job tasks in a safe and secure environment

▶ 50% reduced downtime

• Remote service technicians can rapidly access critical information and enable collaborative solutions

• Allows you to “see what I see” andannotate in a shared workspace leveraging Vuforia Chalk

▶ 50% reduce downtime

Digital Engineering

Smart Connected Machine Solutions

Maintenance workflows Enhanced Operations Remote Assistance

Reduce Costs

Throughput Analysis Machine Prototyping Virtual Commissioning Operator Training Systems

Improve Revenue

Reduce Risks

Add Value

Global competitiveness

The changing globallandscape requires OEMs to reduce the overall capital cost of their equipment to remain attractive.

Analytics

Improving process, quality and

performance

Smart Sensors

Enhancing tracking of materials, people, consumables and

emissions

Mobility

Reducing maintenance costs and improving

personnel productivity

Simulation

Reducing validationcosts and testingengineering ideas

before implementation

AI & Machine Learning

Predicting failuresand increasing yield

AR/VR

Improving collaboration and

making operations safer

Machine as a service

New collaboration technologies allow significant benefit to end users productivity and quality, building stronger relationships between OEMs and end users, and opening up new potential revenue streams for OEMs.

Project & Operational Risk

Highly publicized and expensive incidents worldwide have raised awareness of equipment development and operational risks. OEMs are challenged with mitigating these risks throughout the entire machine lifecycle.

Industrial Internet of Things (IIoT)

OEMs are faced with navigating new IIoT solutions to bring additional value. A crowded market place creates difficulty in sourcing skilled workers and reliable technology partners.

Smart Connected Machines Enhancing support for your end users by collaborating through the equipment’s entire lifecycle

DIAGNOSTICWhy did it happen?

Market-leading industrial innovation

platform to drive digital transformation for

increased operational performance and agility across all

factories

Industry-Leading augmented reality development tools

to improve workforce efficiency and

training

A set of tools built on top of our FactoryTalk

ProductionCentre MES Platform that

target specific needs of Manufacturing

Operations: Performance, Quality, Production &

Warehouse

Self-service visual analysis/ Data Discovery

tool. With Insightful Storyboards may be

saved and shared that runs on any form factor

or device

Data from real-time sources, with the ability

to store and forward data, reducing loss due

to latency. Enables closed loop feedback

applications and provides advanced analytics in the

“hardware stack”

Solve complex Analytics, AI and Machine Learning

problems. Scalable from on-premise

server to cloud based infrastructures. Handles big data and unstructured

data such as text, imagery, audio, etc.

PREDICTIVEWhat will happen?D

ATA

PRESCRIPTIVEWhat should I do?

IOT AR Fit for Purpose Data Analytics Edge Computing Analytics and AI

DemonstrationCreate dynamic system models rapidly with supplied generic objects and imported CAD.

Generate impressive videos and even demonstrate operating systems within a Virtual Reality environment.

SimulationAnalyze system throughput, identify bottlenecks, dimension resources appropriately and understand the system response to operational changes.

Reduce the investment risk with repeatable experimentation.

Virtual CommissioningTake controls testing off the project’s critical path by connecting an accurate dynamic model of the machine or system to real controls.

Verify the logical operation of the controls offline, before building the real system.

6 7

PanelView HMI / FTView SCADA

FT Analytics for Devices

ICM Dynamics

FT Historian & VantagePoint

LogixAI

FT Analytics DataView

Asset Advisor

Analytics

CLOUD / HYBRID / ON-PREMISE

WarehouseManagement

QualityManagement

CPG

PerformanceManagement

IOT Analytics ThingWorx

Rockwell Automation can help you solve your EV battery manufacturing challenges so you can streamline your production line and get the best value for ICT and automation investments.

Supporting Your Business Every Step of the Way

Industry Focused OEM Team

Your reputation rests on building machines and equipment that meet customer demands. Our technical consultants, engineers, and project managers can help you solve key issues and differentiate your company in a competitive global environment.

PartnerNetwork

PartnerNetwork™ members are leading companies that have experience delivering products or services that are designed to work with our solutions. The collaboration among members helps streamline your supply chain, simplify project implementation, and receive the best value for your automation investment.

Providing global support with a local address Helping customers around the world maximize productivity and minimize risks

Training and Support

As your equipment lifecycle changes, so does your need for technical support. We give you the flexibility to choose the level of electronic and phone support you need, when and where you need it. From service to risk assessments, we provide training and support through the entire lifecycle of your automation equipment.

Global Services & Support

24x7x365“Follow-the-sun” SUPPORT

2,600+SERVICE PROFESSIONALS100+ Consultants700+ Field Services Professionals

80+COUNTRIES12 Remote Support Centers18 ISO-Certified Repair Centers 9 Exchange Hubs

19LANGUAGES SUPPORT

200+TRAINING COURSES

13+ YearsAVERAGE EXPERIENCE

Publication OEM-BRO25A-EN-P - October 2019Copyright © 2019 Rockwell Automation, Inc. All Rights Reserved.

FactoryTalk, iTRAK, MagneMotion, MagneMover, PartnerNetwork and QuickStick are trademarks of Rockwell Automation, Inc. Rockwell Automation are registered trademarks of Rockwell Automation, Inc.

EtherNet/IP are trademarks of the ODVA. All other trademarks and registered trademarks are property of their respective companies.