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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 Chamber ensures precise temperature control, flexible adaptation to different cell types, and minimal maintenance, 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.
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 Smart Formation Chamber is specifically designed for the formation of prismatic and cylindrical battery cells, offering optimized floor loading and space efficiency through a flexible modular concept. It ensures high technical availability with easy maintenance and quick repairs — under 5 minutes MTTR — thanks to replaceable contacting & power electronics modules. With temperature uniformity of ±2°C, the chamber guarantees consistent cell quality. Built-in safety features comply with high standards, and the chamber can be customized to meet specific customer requirements. Additionally, it supports integrated ACIR, DCIR, and OCV testing for comprehensive performance evaluation.
The power electronics of our Smart Formation Chamber provide flexible output ranging from 5A for cylindrical cells to 250A for prismatic cells. Each system is custom-tailored to meet specific requirements, ensuring precise and reliable power delivery for consistently high cell quality throughout the formation process. The implementation of highly efficient power electronics, exceeding 90% efficiency, enables customers to anticipate a reduction in OPEX through the realization of energy cost savings. Furthermore, the intelligent design of our power electronics results in a reduction in capital expenditure, as it necessitates lower copper quantities. The system ensures high cell consistency and process quality through the use of precise accuracy measurement technology, which is achieved through automatic calibration (U: ≤± 0.03%FS; I: ≤± 0.04%FS). With three decades of experience in developing customer-specific power electronics and measurement solutions, the system offers high reliability. Furthermore, the system employs state-of-the-art encryption technology, which sets a benchmark in IT security.
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
Ready to revolutionize your battery production? Join us at CES 2025, from January 7-10 in Las Vegas, to explore how Ai-driven software solutions, innovative process technologies and advanced production equipment can be your game-changer in battery manufacturing.
Tino Schübel | Smart Battery Formation