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M.Sc. Hannes W. Weinmann

Akad. Mitarbeiter
Bereich: Maschinen, Anlagen und Prozessautomatisierung
Sprechstunden: Nach Vereinbarung
Raum: 132, Geb. 50.36
Tel.: +49 721 608-28309
Fax: +49 721 608-28284
Hannes WeinmannIgo8∂kit edu

76131 Karlsruhe
Kaiserstraße 12

M.Sc. Hannes W. Weinmann

Forschungs- und Arbeitsgebiete:

  • Trendforschung zu Zellformaten und Produktionsverfahren für die Elektromobilität
  • Analyse von Technologien und Kernkompetenzen für die Batteriezellproduktion
  • Weiter- und Neuentwicklung von Maschinen- & Handhabungskonzepten für die Batteriezellproduktion
  • Automatisierung der Stapelbildung


Allgemeine Aufgaben:

  • Vorlesungsbetreuer des studentischen Entwicklungsprojektes:
    • Produktionstechnik für die Elektromobilität



  • HighEnergy (BEST) - Beschichtung, Trocknung und neue Stapelbildungsverfahren für High Energy Zellen



  • Einzelblattstapelbildung
  • Versuchsstand zur definierten Beanspruchung von Elektroden und Separatoren für die Batteriezellproduktion


Dissertation: Prozessoptimierung für die Lithium-Ionen Batterieproduktion



seit 11/2016 Wissenschaftlicher Mitarbeiter am Institut für Produktionstechnik (wbk) des Karlsruher Instituts für Technologie (KIT)
04/2014 - 02/2017 Studium des Wirtschaftsingenieurwesen (M.Sc.), Karlsruher Institut für Technologie
09/2014 - 06/2015 Studium der Informationssysteme (M.Sc.), Linnaeus Universität, Växjö, Schweden
10/2010 - 03/2014 Studium des Wirtschaftsingenieurwesen (B.Sc.), Karlsruher Institut für Technologie
1987 Geboren in Kulmbach


[ 1 ] Leitold, L.; Spohrer, A.; Weinmann, H. W. & Fleischer, J. (2016), „Development of ball screw analysis software using MATLAB Simulink“. GAMAX Proceedings, Hrsg. Gamax Laboratory Solutions Ltd., S. 1.
In this report monitoring systems for the feed axes in machine tools, developed in MATLAB Simulink at the wbk Institute of Production Science (KIT, Germany), are presented. Implemented use cases at the wbk are the condition monitoring of ball screw drives, which can be used for the analysis of the feed axes‘ wear-status, and innovative approaches for adaptive lubrication, which can be used for the active prevention of wear as well as for preventive maintenance.

[ 2 ] Weinmann, H. W.; Lang, F.; Hofmann, J. & Fleischer, J. (2018), „Bahnzugkraftregelung in der Batteriezellfertigung“, wt Werkstattstechnik online, S. 519-524.
Viele Maschinen- und Materialparameter sind für die Qualität eines Elektroden-Einzelblattes verantwortlich. Relevant für Vereinzelung und Stapelbildung ist etwa die Bahnzugkraft, mit der die Elektrodenbahn während des Stanzvorgangs beaufschlagt wird. Diese wurde in der Versuchsanlage des wbk Institut für Produktionstechnik regelbar ausgeführt, um Zusammenhänge bei der Einzelblattstapelbildung zu untersuchen. Dieser Artikel stellt Auswahl und Funktion sowie die Integration der Lösung in die Versuchsanlage und die Auswirkung verschiedener Bahnzugkräfte auf die Maßhaltigkeit der gestanzten Einzelblätter vor.

[ 3 ] Preu, R.; Rein, S.; Zimmer, M.; Weinmann, H. W.; Hofmann, J. & Fleischer, J. (2018), „Digitalisierung bei der Produktion von Solar- und Batteriezellen“. Die Energiewende – smart und digital, Hrsg. FVEE ForschungsVerbund Erneuerbare Energien, S. 0-0.

[ 4 ] Bold, B.; Weinmann, H. W. & Fleischer, J. (2018), „Challenges in conveying electrodes and new approaches to quality assurance“. Tagungsband zur International Battery Production Conference 2018, Hrsg. Prof. Arno Kwade, B. L. B., S. 56-57.
Electric mobility is gaining importance in Germany but high battery costs are still an obstacle. The production of battery cells amounts to a considerable share to the total costs and therefore efficiency must be further increased. Within the battery cell production the electrode is processed continuously as an electrode web until stack formation. In the individual process steps the material is guided via deflection rollers, including various compensation systems, which are designed to eliminate unevenness in the web tension and to align the position of the web edge. Such systems are mostly adapted from the paper or film processing industry. However, compared to paper or foil the electrode consists of a composite material consisting of active material and current collector. As a result, the electrode forms a system of complex properties since it consists of two materials with different mechanical properties. The presentation thus gives an overview over available market solutions and sets out why an adaptation is not possible without further ado. It also presents the challenges that occur within the material transport of electrodes. These include the wrap angle, roller diameter and web tension applied. With regard to the material parameters, the distortion of the electrode and the formation of folds are described. Up to now, the electrode behavior has been evaluated qualitatively as there are no measurement methods available. New approaches for optical methods are presented that enable a quantification of the electrode distortion within the electrode web. Three variants are described which show first promising results. By means of image processing and applied colored points their displacement is detected and thus how the electrode deforms in the process. Furthermore, another similar method is presented which works with a sprayed-on pattern and a software from the GOM GmbH for evaluation. Since these methods do not allow for an in-line quality evaluation a further variant is being considered in which the deformation of a laser pattern projected onto an electrode is assessed. Finally, a description of the material flexibility with respect to the measurement methods is given, as this will play an important role in the future.

[ 5 ] Weinmann, H. W. & Fleischer, J. (2018), „Highly integrated machine module for single sheet stacking“. Tagungsband zur International Battery Production Conference (IBPC) 2018, Hrsg. Prof. Arno Kwade, B. L. B., S. 58.
The number of electrified vehicles and portable electronic devices announced by manufacturers is rising continuously. This inevitably leads to an increase in demand for battery cells, whereby the pouch cell is particularly well suited for some applications since it offers for example the advantage of higher format flexibility, due to the cell assembly from individual sheets, and the possibility to process thick-film electrodes. The breakthrough of the pouch cell format is currently counteracted by the comparatively high production costs which are largely attributable to the time consuming process steps of separation and assembly. The general challenges in the production for pouch cells lie in the fast and damage-free separation and positioning of the individual sheets (anode, cathode, separator) relative to each other. Thick-film electrodes and increasingly thin separators place additional demands on the production process. Thick-film and heavily calendered electrodes for example exhibit higher rigidity, resulting in new challenges for material guidance, handling and separation. According to the state of the art, electrodes and separators are often cut using lasers. This procedure favors the formation of particles which are difficult to remove from clean and dry rooms. After assembly, the individual sheets are oftentimes temporarily stored in magazines, whereby tolerances in the magazines lead to degrees of freedom and finally to a loss of the previously defined orientation and position. The contact between the magazine guide and the single sheet can also cause damage to the material, especially on the edges, just like those additional process steps for realignment and positioning of the single sheets on the cell stack. The aim of the presentation is to present a systematic derivation of a new and efficient process for forming single sheet stacks considering process related requirements. In particular, feeding and alignment of the material web as well as the separation and positioning of the individual sheets on the cell stack will be addressed. The new process is to be implemented in a highly integrated machine module that incorporates the functions of separating, conveying and depositing for electrodes or separators and thus enables a significantly reduced number of process steps. Furthermore, magazines and subsequent alignment of the electrode or separator sheets prior to cell stacking can be dispensed with. The new module should also be explicitly suitable for processing thick-film electrodes and allow a variation of the individual sheet size in one dimension. The higher format flexibility and efficiency achieved by the new process should help to further strengthen the application fields of pouch cells and at the same time reduce production costs.

[ 6 ] Singer, R.; Weinmann, H. W.; Fleischer, J.; Smith, A. & Wiegand, O. (2018), „Function validation of an alternative and format flexible pouch cell packaging“. Tagungsband zur International Battery Production Conference (IBPC) 2018, Hrsg. Prof. Arno Kwade, S. 21.
Due to their outstanding technical properties, lithium-ion pouch cells are used as energy storage devices in electric vehicles. According to the current state of the art, these are manufactured primarily in rectangular footprints and electrically connected in cuboid battery modules to form a battery system. This has the disadvantage that the limited installation space in electric vehicles and portable devices cannot be used ideally, especially for vehicles manufactured according to the conversion design. A forward-looking research approach is therefore to produce the pouch cells in different geometries so that the installation space can be used in the tightest possible packaging. A challenge at this point is the housing of the pouch cells, which consists of a thin aluminum composite foil. Deep-drawing, the state of the art process used to produce this packaging for pouch cells, is only partially suitable for the production of format-flexible packaging that fits close to the contour of the electrode stack. For this reason, the wbk Institute of Production Science has already developed an alternative packaging design (folded pouch packaging) that meets the requirements for format-flexible pouch cells. However, the functionality of the folded pouch packaging pouch packaging could not yet be finally confirmed on a real pouch cell. This will be presented within this poster. In the first step, a geometric cell format is defined to validate the folded pouch packaging. A geometry is chosen that does not make the realization of the pouch packaging too complex. Due to the demand for gas tightness, complex folding templates for the folded pouch packaging may be necessary. The electrode stacks are stacked in a dry room atmosphere from common electrode and separator materials from individual sheets. The arresters are mounted on these sheets and, after integration of the electrode stack, nearly all sides of the packaging are closed. At least, one side of the packaging remains open so that electrolyte can be filled into the cell. Then the final sealing takes place, followed by the formation of the cell. During this process, gases are formed which must be removed from the gas pocket of the folded pouch packaging after formation. This is followed by the aging process. The data generated in this way can be used to validate the functionality of the alternative pouch cell packaging.