In industrial lithium‐ion battery manufacturing, patterned structured electrodes are required due to subsequent processes. In particular, novel and advanced cell stack formation processes cause challenging design requirements for electrode geometry. This work examines the influence of coating speeds up to 50 m min–1 and wet‐film thicknesses up to 400 µm on the coating edge quality. To determine the coating edge quality, the start‐up length in every pattern in the coating direction is compared for different coating parameters. Parameters such as speed and film thickness show no limiting effect, which makes high process speeds possible.

Due to increasing energy and power densities, new fields of application for lithium-ion battery cell technology are constantly emerging. However, the energy and power densities that can be achieved on a laboratory scale are often limited by the industrially available production equipment. The growing demand, especially for high-energy cells, also reveals a deficit in production technology. The systems currently available on the market are often unable to process corresponding materials, which increasingly poses challenges for cell manufacturers. Unfortunately, many products that can be manufactured on a laboratory scale currently fail due to their manufacturability on an industrial scale. Within the HighEnergy project, the wbk - Institute of Production Science has dealt with the processability of thick-film electrodes and is also conducting research with respect to the influence of increasing degrees of calendering on the subsequent process steps, especially with regard to the formation of single sheet stacks. The aim of this presentation is therefore to give an overview on influences of increasing coating thicknesses and calendering degrees on the stacking process and to demonstrate various process interactions. In particular, the material guidance and alignment, the separation and the positioning of the individual sheets on a cell stack will be examined more closely. Different requirements which the materials place on the production process will also be examined, e.g. how different web tensions depending on the calendaring degree lead to different levels of dimensional accuracy in single sheet cutting. Finally, it will be shown how these versatile findings can be integrated and how they lead to a process model. This model forms the basis for a statement about the processability of novel or changing materials.

The manufacturing costs for fiber reinforced polymers (FRP) are one of the main challenges in regard to increasing the production capacity. The finishing processes range from introducing holes and pockets for subsequent joining operations to trimming edges to obtain the final contour to separating parts after the molding process. For all these machining processes, the anisotropic properties and layered structure represent key challenges. Characteristic damage types resulting from machining are delamination, fiber pull-out, fraying and spalling. This chapter presents an overview of the machining processes with the current state of the research, followed by results from experiments conducted in this study with the newly proposed CoDiCoFRP.

The preforming of the raw material before moulding causes a large potion of the production cost of FRP components. The main reason for this are the numerous small steps which have to be conducted. Most of them are hard to automate and non-value adding, e.g. the removal of a backing foil from precut raw material. In this chapter, researach on the automation of these steps and their integration into value adding steps is presented.

Durch die erhöhte Nachfrage an elektrischen Traktionsmotoren steigen die Anforderungen an die Produktionstechnik. Die Mehrachsnadelwickeltechnik spielt dabei eine wichtige Rolle, da sie es ermöglicht Vollblechschnittstatoren vollautomatisiert zu bewickeln. Die manuelle Erstellung eines NC-Programms nimmt viel Zeit in Anspruch, was eine kritische Hürde für den Prototypenbau darstellt. In diesem Beitrag wird eine CAD/CAM-Schnittstelle vorgestellt und validiert, die es erlaubt aus den CAD-Daten sowie dem Wickelschema automatisiert ein Wickelprogramm zu erstellen.