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Smart Battery Formation combines highly efficient power electronics with intelligent energy management to significantly reduce the operating costs of the battery cell formation process. Its modular design kit allows for adaptation to various customer requirements, from standalone solutions to gigafactories.
Battery formation is a key process in enhancing cell performance and stabilizing cell chemistry. Our Smart Battery Formation solution integrates high-efficiency power electronics and intelligent energy management to significantly lower operating costs while maximizing energy efficiency and production quality. The modular design kit of our Smart Formation station ensures minimal maintenance, precise temperature control and flexible adaptation to different cell types , resulting in consistent cell quality and reduced downtime. Additionally, our Warehousing and System Design offers a flexible layout that optimizes space utilization and operational flexibility, further reducing costs through intelligent energy reuse.
Our solution combines the flexibility of customized systems with the efficiency of a proven, modular industrial platform. With configurable functional modules, we create manufacturing solutions precisely tailored to your needs — from cell type and workpiece carrier design to specific process requirements like heating, cooling, and more.
The modular architecture enables fast implementation, minimizes engineering effort, and offers maximum adaptability. Each solution is developed in close collaboration with our customers — technically robust, economically sound, and scalable for future growth.
Integration into your enterprise IT systems (e.g., MES, ERP) is optionally available, depending on project requirements. Comprehensive after-sales support — from commissioning and ramp-up assistance to training and spare parts — ensures reliable operation and long-term performance from a single source.
Our formation solution enables maximum product quality through high-precision measurement and control technology. Electric current, voltage, and temperature are captured and processed with high accuracy — with temperature monitoring performed both centrally in the power electronics area and individually at each battery cell.
Each cell is individually controlled, allowing for precise adjustment of process parameters. This significantly improves the consistency and quality of cell formation.
Comprehensive data acquisition and analysis at the cell level provide a transparent foundation for further optimization — including the optional integration of AI-based analytics to enhance efficiency, quality, and process reliability.
Our formation solution combines maximum energy efficiency with a future-ready system design. The integrated power electronics achieve an efficiency of over 90%. At the same time, more than 80% of the electrical energy used is recovered and effectively reused. This measurably reduces energy consumption and lowers operating costs — reliably and long term.
In systems with multiple formation chambers, intelligent control enables targeted energy distribution and optimized chamber allocation during process start. This significantly reduces overall energy consumption and sustainably improves load management.
In addition, surplus electrical and thermal energy can be repurposed in a targeted way — enabling added value and contributing to a more resource-efficient and energy-conscious production process.
The warehouse and system design offers a flexible layout that can be adapted to suit customer requirements and the layout of the plant in a given location. The design also results in reduced OPEX, which can be attributed to the reuse of energy in excess of 80% facilitated by an intelligent energy flow concept between chambers. Furthermore, the design includes a software system that enables efficient operations and offers an optional interface to enterprise IT. Additionally, the solution provides optimized floor loading and space efficiency through a modular concept.
Our Formation Control System is a modular software solution designed to control and optimize the battery cell formation process. It provides centralized management of recipes, process data, quality tracking, maintenance activities, and energy usage — all within one integrated portfolio. It enables bidirectional communication with each formation station, ensuring consistent data exchange and full transparency across all process steps. The system is scalable and can be operated either on-premise or in the cloud — from standalone stations to fully integrated warehouse-level systems. Thanks to its open architecture, FCS can be integrated into existing enterprise IT environments such as MES or ERP systems.
Optimization of resources and reduction of energy consumption as well as long-term cost reduction through reduction of operating costs and maintenance expenses
High reliability and process quality thanks to 30 years experience in industrialization as well as the development of customer specific power electronics and measurement solutions
Versatile use thanks to flexible adaptation to different requirements and usage scenarios
Tino Schübel | Smart Battery Formation