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Get a quoteFrom the individual battery cell to the assembly of complete battery packs: With many years of expertise, KUKA covers the entire value chain in battery production systems and supplies
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In this process step, lithium-ion cells are assembled into modules and connected in series or in parallel. KUKA supplies the turnkey system and keeps an eye on everything: In addition to optimal handling and welding solutions, adhesive bonding, pressing and electrical and thermal contacting are relevant key processes here.
Low-cost lithium-ion battery cells (LIB) are the key to mass electromobility, although the manufacturing process has always been a cost driver – until now. Researchers at TU Berlin are using continuous Z-folding to replace the traditional pick-and-place movements that have been used so far, thereby accelerating battery cell production.
In the production of lithium-ion battery cells, special high-precision machines are used for individual production steps. KUKA robots can take over certain key processes such as stacking, loading and unloading, or formation and aging of cells.
Demand for lithium-ion batteries is booming. From smartphones and tablets to e-cars: nothing runs without batteries. Accordingly, the required quantities in battery production are increasing rapidly. The solution lies in automation. This is because the manufacture of batteries is technically demanding and requires high safety standards.
Our approach involves the use of a central PC-based automation platform to achieve maximum process efficiency in battery cell winding, as this allows vision systems, motion tasks, and communication to I/Os to all be controlled with a high level of synchronicity. It also enables precise winding accuracy while maintaining high output.
The global industrial and commercial energy storage market is experiencing unprecedented growth, with demand increasing by over 350% in the past three years. Energy storage cabinets and lithium battery solutions now account for approximately 40% of all new commercial energy installations worldwide. North America leads with a 38% market share, driven by corporate sustainability goals and federal investment tax credits that reduce total system costs by 25-30%. Europe follows with a 32% market share, where standardized energy storage cabinet designs have cut installation timelines by 55% compared to custom solutions. Asia-Pacific represents the fastest-growing region at a 45% CAGR, with manufacturing innovations reducing system prices by 18% annually. Emerging markets are adopting commercial energy storage for peak shaving and energy cost reduction, with typical payback periods of 3-5 years. Modern industrial installations now feature integrated systems with 50kWh to multi-megawatt capacity at costs below $450/kWh for complete energy solutions.
Technological advancements are dramatically improving energy storage cabinet and lithium battery performance while reducing costs for commercial applications. Next-generation battery management systems maintain optimal performance with 45% less energy loss, extending battery lifespan to 18+ years. Standardized plug-and-play designs have reduced installation costs from $900/kW to $500/kW since 2022. Smart integration features now allow industrial systems to operate as virtual power plants, increasing business savings by 35% through time-of-use optimization and grid services. Safety innovations including multi-stage protection and thermal management systems have reduced insurance premiums by 25% for commercial storage installations. New modular designs enable capacity expansion through simple battery additions at just $400/kWh for incremental storage. These innovations have significantly improved ROI, with commercial projects typically achieving payback in 4-6 years depending on local electricity rates and incentive programs. Recent pricing trends show standard industrial systems (50-100kWh) starting at $22,000 and premium systems (200-500kWh) from $90,000, with flexible financing options available for businesses.