ENERGY & BATTERIES
Battery Manufacturing Automation
Controls optimization and robot integration for EV battery module manufacturing. Mitsubishi PLC logic refinement, HMI development, and global engineering coordination—improving cycle time and production reliability.
Samsung SDI | Michigan, USA
THE CHALLENGE
Battery Manufacturing Challenges
Cycle Time Pressure
Production demand was increasing, but cycle times were not meeting targets. The existing PLC logic had inefficiencies that accumulated across hundreds of daily cycles.
Integration Complexity
The manufacturing cells included Mitsubishi PLCs, multiple robot brands, vision systems, and HMIs—all needing to communicate seamlessly with global engineering systems in Korea.
Diagnostic Visibility
When issues occurred, operators and maintenance lacked clear visibility into what was happening. Troubleshooting took too long, extending downtime.
Precision Requirements
Battery cell handling requires extreme precision. Placement accuracy of ±0.05mm was required, with zero tolerance for cell damage during handling.
OUR SOLUTION
Our Battery Automation Solution
Mitsubishi PLC Optimization
We analyzed and optimized the existing PLC logic for battery manufacturing cells.
- Identified and eliminated redundant logic sequences
- Optimized motion profiles for robot coordination
- Improved interlock timing to reduce wait states
- Refined error handling for faster recovery
Robot Integration
Working with multi-brand robot cells, we ensured seamless coordination.
- Robot-to-PLC communication optimization
- Path refinement for precision placement
- Collision avoidance verification
- Cycle time analysis and improvement
HMI Development
We developed enhanced HMI screens for operators and maintenance.
- Real-time cell tracking visualization
- Diagnostic screens with clear fault identification
- Production metrics dashboards
- Maintenance alerts and PM scheduling
Global Coordination
We collaborated with Samsung SDI's engineering teams in Korea and the US.
- Participated in daily engineering calls
- Documented all changes per Samsung standards
- Validated modifications through Samsung's approval process
- Supported remote monitoring integration
SPECIFICATIONS
Battery Manufacturing Technical Details
THE RESULTS
Battery Automation Results
Optimized PLC logic and robot coordination reduced average cycle time by 35%, increasing daily production capacity.
Refined handling sequences and precision verification maintained zero cell damage rate throughout production.
All placement accuracy requirements were met consistently, validated through automated vision inspection.
New HMI screens reduced average troubleshooting time by 40%, getting lines back to production faster.
Battery Manufacturing Services
Need Battery Manufacturing Automation?
EV battery production demands precision, reliability, and speed. Our automation engineers have the experience to help you achieve all three.
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