How Battery Manufacturing Will get Sensible

Experience in the field of internal batteries is one of the success factors as the power generation process of power generation continues to progress. (Photo: BMW)

At the start of the Car Production Conference 2022, Lower Saxony’s Minister for Economic Affairs, Labour, Transport and Digitalization, Bernd Althusmann (CDU), emphasized that there are also many opportunities in electric mobility as well as risks. Battery cell production is high According to the minister, depending on the resources of other countries, it is important to pay close attention to the production cycle. So Volkswagen is absolutely right about the Salzgitter position and battery production.

The world’s second largest automaker with its many brands is currently on the throttle when it comes to e-mobility: in Europe alone, Volkswagen plans to build six giga plants by 2030. Together with Bosch, Lower Saxony is striving to Establishment of a European supplier of battery cell plant equipment on me. Only at the beginning of the year, the group announced the signing of a similar declaration of intent, with which one wants to explore in-house manufacturing solutions for the project.

Hardly any other subject occupies the industry as much as electricity, asserts Martin Linder, McKinsey & Company’s senior partner in industry. During the Hannover Fair. The market expert is currently seeing a veritable battery ecosystem in the making. In 2030, a global sales share of 60 percent for electronic cars has been assumed, which means the launch of about 700 models and thus tremendous growth. McKinsey sees a market size of about US$450 billion in 2030, from raw materials and refining to packaging and recycling. According to market watchers, the required capacities in battery production will increase from 49 GWh in 2020 to about 970 GWh in 2030 in Europe alone.

However, the capacity will not come from established players alone. About a third will be contributed by start-ups that don’t have any battery experience, Linder says. So the structure is for the market expert Local supply chains are a must. According to him, the big problem is sometimes very rare and expensive raw materials. For lithium alone, the price has gone up fivefold. In addition, it is important to consider planning uncertainty due to new battery technologies. According to market experts, success factors include a modular structure of production sites, intelligent use of data within the framework of the PLM, intelligent sensing technology in production, digital twins and process data analysis, as well as early-stage strategic partnerships and internal competency development.

Large OEMs rely on their own experience

Jörg Pozer, member of the board of directors of the Mercedes-Benz Group, Production and Supply Chain Management, rules out the creation of private e-mobility factories. Instead, existing sites are shifted in the direction of e-navigation. Of course, the council says, it is possible in the next three years to see assembly halls completely converted to electronic mobility. This is subject to the corresponding domestic market situation. Mercedes is relying on flexible lines to meet the growing demand for electric motors. As part of its electrical offensive, the manufacturer has increased its global capacity to produce batteries and approx Production of batteries for models such as EQS Designed to meet needs.

A similar philosophy is also implemented with regard to electric mobility at rival BMW: all types of drives are manufactured in a single line at the Bavarian OEM plant – regardless of whether it is the Debrecen plant, which has just opened during the Hanover fair, or the main plant in Munich, Which is now 100 years old. The original device manufacturer develops a deep understanding of the entire battery system in-house, Armin Ebner explains, Head of Production System, Digitization, Operational Excellence. BMW only opened Battery Efficiency Center in 2019, these days now Battery cell production center in Barsdorf near Munich. According to the OEM, the company does not intend to engage in actual cell production, but it is already making high-voltage batteries, battery modules and components at German factories in Dingolfing, Regensburg and Leipzig. Other electronic driving ranges are located at the Spartanburg plant in the USA and at the BMW Brilliance Automotive joint venture in China.

Factory Suppliers and New Staff Wanted

However, building your own battery expertise requires significant factory building skills, says expert McKinsey Linder. There is still supremacy in the Asia Pacific region. There is opportunity here for the United States and Europe. Market experts see another uncertainty factor in the actual cell technology: because new battery technologies bring uncertainty into the planning that must be taken into account. In addition, with the new drive systems for pure electric vehicles with large battery packs on board, the manufacturing processes that are considered specific are also changing, for example in the panel.

Electric cars have a modified sill structure that makes it difficult to apply paint the classic way when driving lengthwise, explains Jochen Werauch, chairman and CEO of system manufacturer and paint expert Dürr at an automobile production conference. Using new technology, car bodies to be painted are driven straight through the factory and heated from the inside. The CEO can also consider battery production Special expertise from Dürr in electrode processing point out. For example, Dürr has perfected a double electrode coating process In one practical step – a non-trivial process, Werauch emphasizes, the electrodes must also be dried while they are floating.

A factory construction company that has positioned itself strategically in recent years to be in the future It can offer technologies for the complete powertrain of an electric vehicle, It is the business of the Mindelheim-based Grob. From electric motors and battery units to battery cells, Bavarians, who trace their origins back to manufacturing, cover the new processes of electric mobility.

This should give the company a safe path forward. According to expert McKinsey Linder, some suppliers of entire systems and machinery are booked out for up to a year and a half. In addition to the machines required to deal with the subject of electronic mobility, Linder also refers to people, because people with the appropriate electrical expertise are more in demand than ever. According to the consultant, around 100,000 employees in Europe alone will be needed to cover demand by 2030.

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