Cutting-edge Electric Vehicle Battery Production using Hepco’s V Guide Systems

The composition of an EV battery varies depending on the type of electric vehicle, but generally, EV batteries are composed of individual battery cells and modules which come together to form a pack. The battery for a BMW i3 for example comprises of 96 battery cells. Twelve cells are combined into one module and eight modules come together to form one pack. The manufacture of EV batteries therefore requires many elements to be combined together making it particularly suited to long line manufacturing. Space is often at a premium however, making a compact, space-saving system high on the agenda. Production formats vary but the key EV battery manufacturers all use a vertical closed loop track layout, which offers significant benefits by optimizing the space in a 3D capacity. The footprint remains the same but production can be doubled by having two productions lines running in parallel, vertically aligned, one above the other. A small length of track, vertically moved by an actuator connects the lower and upper tracks. Not only is this system space saving but it also maintains the product in a single orientation; advantageous in EV battery production.

With a vertical closed-loop track layout there is a small gap between the main production line and the short length of track that moves vertically to connect the upper and lower tracks. A traditional conveyor system or a ball rail system for example, are not able to cope with this gap. Indeed, it can be challenging for many linear guidance systems to cope with gaps and provide the seamless guidance required for the carriage to traverse. Hepco’s V guide systems are able to traverse joints or gaps making them a popular choice in EVB applications.

Typically operating at 1m/s with a 20kg payload, the movers move around the system via dynamic track sections that vertically align with adjacent tracks, providing a sizeable flow process through various stages of production. SK Innovation use Hepco’s 6 bearing carriages, which are able to traverse gaps as four bearings are always in contact with the rail when traversing the gap, keeping the carriage parallel. A centrally mounted linear motor unit independently moves the carriages, providing complex sequences of movement for individual carriages.

Leading Korean Chemical company, LG Chem also use Hepco’s GV3 linear guide in their automated system producing EV battery film. Again a vertical closed-loop system is employed and the GV3 linear guides are supplied as butted sets to fulfil the 20m circuit. With a wide portfolio of products and a variety of different configurations ideally suited to EV battery manufacture including singe-edged slides, 6 bearing carriages, and assembled carriages with added top-plate, HepcoMotion has a solution to meet practically any requirement.

One of the biggest challenges in the EV industry is producing the output to match the demand. This is an exponentially growing market and as with all applications requiring high throughput, low maintenance is core to optimizing production processes. A low maintenance solution means less manpower, less downtime which equates to a significant cost saving. Conveniently, when a Hepco V system shows sign of wear, the process is simple and does not impinge too much on production time. The eccentric adjustment facility of the V bearings can be used to quickly and simply remove any play that has occurred. Moreover, when the V bearings reach the end of their calculated life, they can be replaced individually, and not as an entire set, saving both time and money. A key point to note is that a V guide system will not fail catastrophically meaning excessive downtime and a complete system change will be avoided.

This application requires a consistent level of precision to ensure SL2 carriages, which carry the product are aligned correctly to production equipment and processes. Operating at 2m/s with an 80N payload, this is a high duty application.

A further reason why Hepco is often favoured in this type of application is due to its high compliance.

As electric vehicles continue to move towards becoming a viable choice for mainstream drivers, the long-term outlook on the electric vehicle battery market looks positive. With end users including SK Innovation, LG Chem and Samsung SDI, Hepco’s V guide systems meet the demanding needs of the biggest EV battery producers, and are a key production element contributing to a cleaner, environmentally friendly future.