From simulation to production: Digital plant planning and efficient automation solutions for a high-quality battery manufacturing

Transcription

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

2 Prospects for the battery market Value added chain and process Automation technology and expertise Linear integration and connection to the control level The factory of the future Page 2

3 Barriers and challenges for the battery industry and machine building Rapid growth Economic challenge Shortage of crude oil Climate change Public Sponsorship/regulation Urbanization Decline of marginal unit cost Transport costs High quality Global markets Changing technology Complex value added Form factor Further development of cell chemistry Service life/ charging cycles Energy density/weight Hybrid industry Complex production Quality measurement Machine integration Page 3

4 Technology leaders must predict the future Industrial development 200x Pilot machine Control of individual processes Individual machine Interlinking, quality measurement Inline machine Horizontal integration, KPI (quality), SCADA Linear solution Horizontal/vertical integration, KPIs (quality, production), SCADA, MES 202x Next generation Challenges Form factor + cell chemistry Reproducibility Complex production Quality Productivity Global markets Machine Scale effects Electrochemical integration developments Economic challenges Market Process Networks Measuring technology Science & research Export Transparency of production Standstills Efficiency Time-to-market Page 4

5 The global market potential for traction batteries will rise sharply until 2025 Global market for lithium-ion traction batteries Regions Drive segments Global market 2025 [$ billions] Other Japan 5% 7% 21% Europe MHEV E-bike SHEV 3% 3% 11% 40% EV China 46% 21% NAFTA PHEV 36% 7% REX Cell materials Cells Packs Europe Japan EV SHEV "Slow" scenario NAFTA Other REX MHEV "Moderate" scenario China PHEV E-bike Source: A.T. Kearney (10/2012) MHEV = Mild Hybrid Electric Vehicle SHEV = Strong Hybrid Electric Vehicle PHEV = Plug-in Hybrid Electric Vehicle REX = Range Extender EV = Electric Vehicle Note: Cells including cell materials, packs including cells, battery management system and cooling; split between regions and drive segments refers to packs Page 5

6 Battery costs are crucial in transforming a trend into the mainstream 2,000 1,750 1,500 1,250 ~ $1,100 1,000 ~ $ ~ $ Scenario Development of lithiumion battery costs for electric vehicles ($ per kilowatt hour (kwh) pack level) $281 High Average Low Source: OEM and supplier interviews conducted in Asia, Europe and North America; McKinsey analysis Fully automated and linked production lines are required to achieve the cost target. Page 6

7 Prospects for the battery market Value added chain and process Automation technology and expertise Linear integration and connection to the control level The factory of the future Page 7

8 Value added chain in battery manufacturing Page 8

9 Inline measurement - the key for a high quality production Electrode manufacture Cell manufacture Fault sources Contamination Proportioning Viscosity Layer thickness Edges Particles Drying Porosity Adhesion Layer thickness Porosity Cutting burrs Broken edges Dirt High dynamic response Separating Stack position Dirt/burrs Blistering Proportioning Distribution Contacting Overcapacity/ undercapacity 1 Mixing 2 Coating 3 Compression 4 Drying 5 Slitting/ punching 6 Cell assembly 7 Addition of electrolyte 8 Formation/ aging 9 Test/ categorization R R Measuring method Physical Silas, rheology viscosity Mechanical Scales Chemical ICP-MS* GC** Radiometric Beta radiation Optical Camera Laser Optical Camera Laser Optical Camera * Inductively coupled plasma mass spectrometry ** Gas chromatography Electrical High potential Physical Tension: Zwick X-ray Optical Camera Mechanical Scales Electrical High potential Impedance Current/voltage Pulse power Page 9

10 Prospects for the battery market Value added chain and process Automation technology and expertise Linear integration and connection to the control level The factory of the future Page 10

11 Totally Integrated Automation for Battery Production. For all steps in the battery value added chain SIEMENS offers a wide automation portfolio! Page 11

12 Example: electrode coating (I) Requirements Flexible, double-sided, intermittent strip coating at up to 50 m/min: Homogenous coating thickness of µm Tolerance for coating of 1-2 µm Prevention of build-ups at the start and end of the coat Integrated quality inspection of coating thickness, area mass, and surface structure Optional integrated calendering of the electrode (inline) Fast adaptation of the process in the case of quality flaws Constantly high speed of the winder drives Automatic roll change Integration into plant network Automation solution Coating system II Coating system I Reversing unwinder Machine Dryer Reversing winder Continuous Intermittent Strip Intermittent and strip Customer benefits SIMATIC S7 (F) Machine automation SINAMICS S120 Standard applications PROFIsafe SINAMICS DCC Winder SINAMICS DCC Line Tension Control PROFINET I/O: ET200 (F) SINAMICS S/G: Auxiliary drives (AC/AC) e.g. 1FK7 motor series for material transport and winders SINAMICS DCC RGJ (ramp-function generator with jerk limiting) SINAMICS DCC Accumulator Flexible and fast control of the coating system with SIMATIC S7 for high-precision coating Easily 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 storage Controllers, drives and motors scalable for all requirements and power ratings Simple and safe integration of quality measuring systems into the automation solution on Profinet based on Standard Ethernet Page 12

13 Example: Electrode manufacturing (II) Coating, Quality check* Process Integration e.g. speed Fault condition Message text Removing of faulty parts MES- /ERP- SCADA- Machine Level Mixer Effects on Coating Quality Check Effects on Slitter / Puncher Nachfolgender Prozess- Schritt KPI analysis SCADA system with embedded MS SQL-Server. Downtime-Monitor Predecessor Successor Measuring points Page 13 Process Step Quality Control Measurement Solution Measurement Layer thickness, mass per unit area distribution Measuring technique Continuously via Beta radiation Notification Max-, Min-, Average, Variance, Worse Application Detection and identification of faulty material parts Process optimization Reporting KPI: Quality PC based application - measurement and analysis within one automation device Simple integration into already existing structures because of same system environement Simatic S7 Reuse of existing know how Source: betacontrol

14 Prospects for the battery market Value added chain and process Automation technology and expertise Linear integration and connection to the control level The factory of the future Page 14

15 Detection and analysis of the product- and process quality Questions by plant operators Our solution 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? 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. Page 15

16 More transparency from the machine to the corporate level Visualization Trends Machine availability Maintenance SCADA / MES system User-specific preparation of all the relevant machine, plant and product data OEE / KPI view Messages, alarms Reports System diagnostics Adapter Integrated communication between all machines and the control room Mixing Coating Compression Drying Slitting/punching Cell assembly Visualization, quality control, calculation of key statistics (KPI, OEE) Linear integration makes an essential contribution to reducing costs while simultaneously increasing the quality of the battery cells produced Page 16

17 SIMATIC WinCC SCADA-System Battery Demonstration - System Page 17

18 SIMATIC WinCC SCADA-System Battery Demonstration - System Detailed Process View KPI-View Messages, Alarms Trend View Trend overview about the machine Page 18

19 Prospects for the battery market Value added chain and process Automation technology and expertise Linear integration and connection to the control level The factory of the future Page 19

20 Faster from the product idea to production on the basis of an integrated chain of engineering tools Yesterday Today Tomorrow Process level in series in series, shortened by tools parallel Product Procedure Mechanical system Electrical system Automation Planning Mechanics Commissioning Time Time Time Fast response to new product requirements Page 20

21 The intelligent factory Seamless product and production life cycle Product use/service Product requirements Product design Optimization, maintenance Real Production design Digital Manufacture Virtual commissioning Simulation Page 21

22 Delivering value across the entire product lifecycle Siemens PLM Software features three product lines: NX for digital product development TECNOMATIX for digital manufacturing Page 22 TEAMCENTER for digital lifecycle management

23 Plant simulation with Tecnomatix Plant Simulation Simpler planning, faster analysis, safer decision-making Graphical modeling, visualization, simulation and optimization of the production, logistics and business processes in battery manufacture Page 23

24 Benefit from having a strong partner Products, solutions, service and industry know-how from a single source The range from Siemens for machine manufacture in the battery industry: A Products Extensive automation and drives portfolio for open and integrated automation concepts in the battery industry (TIA) B Technology Expertise Decades of experience with the core technologies for battery manufacture in other industries such as converting in the paper industry C Battery expertise Know-how in the battery industry: From the process through automation right up to cell chemistry with references at all stages of the value added chain D Global network We bring supply and demand together and provide support in training, consulting, and networking. We like to promote our partners! Page 24

25 Thank you for your attention! Dr. Thomas Aigle Fachvertrieb Erneuerbare Energie Region Südwest Siemens AG Lise-Meitner-Str Ulm Telefon: +49 (731) Page 25