from simulation to production: digital plant planning and ... · pdf file© siemens ag...

© Siemens AG 2013. All rights reserved. www.siemens.com/battery

From simulation to production: Digital plant planning and efficient automation solutions for a high-quality battery manufacturingDr. Thomas Aigle, SIEMENS AG – 30.09.2013, World of Energy Solutions, Messe-Stuttgart

© Siemens AG 2013. All rights reserved.30.09.2013 Dr. Thomas Aigle Industry Sector

• Prospects for the battery market

• Value added chain and process

• Automation technology andexpertise

• Linear integration and connection to the control level

• The factory of the future


Barriers and challenges for the battery industry and machine building

Complex value added

Economic challenge

Changing technology

Rapid growthShortage of

crude oil UrbanizationPublic Sponsor-ship/regulationClimate change Decline of

marginal unit cost Global marketsHigh qualityTransport costs

Form factor Energy density/weight

Service life/charging cycles

Further development of cell chemistry Hybrid industry Machine

integrationQuality

measurementComplex

production


Technology leaders must predict the future

NetworksMarket

Process

Measuring technology

Science &research

Transparency ofproduction

Export Standstills

Efficiency

Time-to-market

Indu

stria

l dev

elop

men

tEc

onom

ic

chal

leng

esC

halle

nges

Inline machineHorizontal integration, KPI (quality), SCADA

Individual machineInterlinking, quality measurement

Reproducibility Productivity

Pilot machineControl of individual processes

Linear solutionHorizontal/vertical integration, KPIs (quality, production), SCADA, MES

200x 202xNext gene-ration

Complex production

Form factor +cell chemistry

Quality Machine integration

Global markets Scale effects Electrochemicaldevelopments


The global market potential for traction batteries will rise sharply until 2025

Global market for lithium-ion traction batteries

MHEV = Mild Hybrid Electric VehicleSHEV = Strong Hybrid Electric VehiclePHEV = Plug-in Hybrid Electric VehicleREX = Range ExtenderEV = Electric Vehicle

0

20

40

60

80

100

120

140

160Europe

Japan

ChinaNAFTA

Other

46%21%

21%5%

7%

Regions

SHEV

MHEV E-bike

EV

REX

PHEV

36%

7%

40%

11%

3%3%

Drive segments

Europe

NAFTA

China

Japan

Other

"Slow" scenario

"Moderate" scenario

EV

REX

PHEV

SHEV

MHEV

E-bike

Source: A.T. Kearney (10/2012) Note:Cells including cell materials, packs including cells, battery management system and cooling; split between regions and drive segments refers to packs

Cell materials

Cells Packs

Global market 2025 [$ billions]


Battery costs are crucial in transforming a trend into the mainstream

750

1,000

1,250

1,500

1,750

2,000

0

250

500

2025 20302006 2010 2015 2020

$281

Development of lithium-ion battery costs for electric vehicles ($ per kilowatt hour (kWh) pack level)

Source: OEM and supplier interviews conducted in Asia, Europe and North America; McKinsey analysis

High

Average

Low

Scenario

~ $1,100

~ $720

~ $390

Fully automated and linked production lines are required to achieve the cost target.


Value added chain in battery manufacturing


Inline measurement - the key for a high qualityproduction

Cell manufactureElectrode manufacture

Cell assembly6 Addition ofelectrolyte7 Formation/

aging8 Test/categorization9Slitting/

punching5Mixing1 Coating2 Compression3 Drying4

ContaminationProportioningViscosity

DryingPorosityAdhesion

Layer thicknessEdgesParticles

Layer thicknessPorosity

Cutting burrsBroken edgesDirt

High dynamic responseSeparatingStack positionDirt/burrs

BlisteringProportioningDistributionContacting

Overcapacity/undercapacity

RadiometricBeta radiation

Optical CameraLaser

Mechanical Scales

PhysicalSilas, rheologyviscosity

ChemicalICP-MS*GC**

Mechanical Scales

Optical CameraLaser

ElectricalHigh potential

ImpedanceCurrent/voltage

Pulse power

PhysicalTension: ZwickX-ray

Optical Camera

ElectricalHigh potential

Optical Camera

R R

Faul

t sou

rces

Mea

surin

g m

etho

d

* Inductively coupled plasma mass spectrometry** Gas chromatography

© Siemens AG 2013. All rights reserved.

Totally Integrated Automation for Battery Production

• .

30.09.2013 Dr. Thomas Aigle Industry Sector

For all steps in the battery valueadded chainSIEMENS offers a wide automationportfolio!


PROFINET

PROFIsafe

Customer benefits

Machine

Automation solution

Requirements

Example: electrode coating (I)

Flexible and fast control of the coating system with SIMATIC S7 for high-precision coatingEasily parameterized standard applications for setpoint-cascade, winder with tension control, etc.Fewer rejects thanks to automatic roll change during operation with reversing winders or goods storageControllers, drives and motors scalable for all requirements and power ratingsSimple and safe integration of quality measuring systems into the automation solution on Profinet based on Standard Ethernet

Flexible, double-sided, intermittent strip coating at up to 50 m/min:

Homogenous coating thickness of 150-300 µm Tolerance for coating of 1-2 µmPrevention of build-ups at the start and end of the coat Integrated quality inspection of coating thickness, area mass, and surface structureOptional integrated calendering of the electrode (inline)Fast adaptation of the process in the case of quality flawsConstantly high speed of the winder drives Automatic roll changeIntegration into plant network

SINAMICS DCC WinderSINAMICS DCC Line Tension Control

e.g. 1FK7 motor series for material transport and winders

I/O: ET200 (F)SINAMICS S/G: Auxiliary drives (AC/AC)

SINAMICS DCC RGJ(ramp-function generator with jerk limiting)SINAMICS DCC Accumulator

Continuous Intermittent Strip Intermittent and strip

Dryer

Reversing unwinder Reversing winder

Coatingsystem II

Coatingsystem I

SINAMICS S120

SIMATIC S7 (F)

Machineautomation

Standardapplications

© Siemens AG 2013. All rights reserved.

Example: Electrode manufacturing (II) Coating, Quality check*

30.09.2013 Dr. Thomas Aigle Industry Sector

PC based application - measurement andanalysis within „one“ automation deviceSimple integration into already existingstructures because of same systemenvironement Simatic S7Reuse of existing know how

MeasurementLayer thickness, mass per unit areadistribution

Measuring techniqueContinuously via Beta radiation

NotificationMax-, Min-, Average, Variance, Worse

ApplicationDetection and identification of faulty material partsProcess optimizationReporting

KPI: Quality

Process Integration

Measuring points

Process Step Quality Control Measurement Solution

KPI analysisSCADA system with embedded MS SQL-Server.Downtime-Monitor

NachfolgenderProzess-Schritt

MES- /ERP-

SCADA-

Machine

Coating Slitter / PuncherQuality CheckMixer

Predecessor Successor

Message text Removing offaulty parts

e.g. speedLevelFault condition

Source: betacontrol

Effects on Effects on


Detection and analysis of the product- and process quality

Our solutionQuestions by plant operators

Central capturing and analysis of all machine and process data.

Determining of key figures for aggregates, machines, and production lines.

Scalable configuration depends on the plant design.

When required the system availability is increasable by redundant systems.

Traceability of any project changes.

What is the current performance rate of the machine? %?

What is the current quality rate of the production?

What is the availability of my plant at the moment?

What losses does the plant incur?

What are the main causes for downtimes?

On average, what is the duration of my plant malfunction?


More transparency from the machine to the corporate level

Integrated communication between all machines and the control room

MaintenanceMachine availabilityTrendsVisualization

System diagnosticsReportsMessages, alarmsOEE / KPI view

User-specific preparation of all the relevant machine, plant and product data

Linear integration makes an essential contribution to reducing costs while simultaneously increasing the quality of the battery cells produced

Visualization, quality control, calculation of key statistics (KPI, OEE)

SCADA /MES system

Adapter

Compression Drying Slitting/punchingMixing Coating Cell assembly


SIMATIC WinCC SCADA-SystemBattery – Demonstration - System


SIMATIC WinCC SCADA-SystemBattery – Demonstration - System

Messages, Alarms Trend View

Trend overview about the machine

KPI-ViewDetailed Process View


Faster from the product idea to productionon the basis of an integrated chain of engineering tools

Fast response to new productrequirements

ProductProcedureMechanical systemElectrical systemAutomation

Yesterday Today Tomorrowin series in series,

shortened by toolsparallelProcess

level

Time Time Time

Pla

nnin

g

Com

mis

sion

ing

Mec

hani

cs


The intelligent factory Seamless product and production life cycle

Production designOptimization, maintenance

SimulationManufacture Virtual commissioning

Product designProduct use/service Product requirements

Digital

Real


Delivering value across the entire product lifecycle…

NXfor digital product

development

TECNOMATIXfor digital manufacturing

TEAMCENTERfor digital lifecyclemanagement

Siemens PLM Software features three product lines:


Plant simulation with Tecnomatix Plant SimulationSimpler planning, faster analysis, safer decision-making

Graphical modeling, visualization, simulation and optimization of the production, logistics and business processes in battery manufacture


Benefit from having a strong partnerProducts, solutions, service and industry know-how from a single source

Prod

ucts

Bat

tery

ex

pert

ise

Glo

bal

netw

ork

The range from Siemens for machine manufacture in the battery industry:

Tech

nolo

gyEx

pert

ise

A

C

D

B

Know-how in the battery industry: From the process through automation right up to cell chemistrywith references at all stages of the value added chain

Decades of experience with the core technologies for battery manufacture in other industries such as convertingin the paper industry

We bring supply and demand together and provide support in training, consulting, and networking. We like to promote our partners!

Extensive automation and drives portfolio for open and integrated automation concepts in the battery industry (TIA)


Thank you for your attention!

Dr. Thomas AigleFachvertrieb Erneuerbare Energie Region Südwest

Siemens AGLise-Meitner-Str. 1389081 Ulm

Telefon: +49 (731) 9450 – 158E-Mail: [email protected]

www.siemens.com/battery

from simulation to production: digital plant planning and ... · pdf file© siemens ag...

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