Motivation and aim

Within the research topic electric mobility, scientists of the wbk Institute of Production Science are working on manufacturing, assembly and handling processes for the production of hybrid and all-electric drive systems. In cooperation with partners from industry and academia both disruptive technologies and established industrial solutions are focused. The main goal of the research is to develop methods and approaches for improved scalability, flexibility and quality control, to automate and optimize manufacturing techniques and processes in the context of battery, fuel cell and electric motor production, and to develop a holistic process understanding for the design of immature process chains in the context of electric mobility.

Battery cell and module:

• Process characterization and optimization – especially in the context of new materials
• Development of agile production systems for scalable battery manufacturing flexible in material and format
• Machine and process development for the automated disassembly of battery modules and cells
• Modeling and simulation of production systems, machines and processes
• In-line and in-process quality control
• Factory and production planning

Fuel cell and electrolyzer:

• Machine and process development for the manufacturing of fuel cells and electrolyzers
• Development and experimental analyses of scalable production and automation concepts
• In-line and in-process quality control
• Factory and production planning

Electric motor:

• Development and numerical simulation of manufacturing process for stators with round and rectangular wire winding
• Process development for the manufacturing rotors with focus on joining, spinning and balancing processes
• Closed-loop control concepts and smart assembly strategies for stator and rotor manufacturing
• Simulation and optimization of cutting processes for efficient high-speed transmissions
• Additive manufacturing of hard and soft magnetic components
• Machine and process development for the automated disassembly of electric traction motor

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