Development, integration and validation of innovative processes and QA-methods in the production of large format lithium ion cells (QS-Zell)

Project duration:
01.08.2016 – 31.07.2019


  • ZSW – Department Production Research (ECP)
  • TU Dortmund University – Chair of Computer-Aided Statistics
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Zentrum für Sonnenenergie- und Wasserstoff-Forschung Baden-Württemberg
Technische Universität Dortmund

One of the biggest challenges in battery cell production is to increase quality while reducing costs. The production of battery cells is a sequence of complex individual processes that can have very different effects on the overall quality. Large-format lithium-ion cells in particular are very susceptible to faults during production. The exact impact of individual processes on overall quality is often only conjectured because there is often ignorance of the relevant process parameters and their tolerances or known influencing parameters cannot be reliably proven. This is where the joint project QS-Zell comes in: The project aims to significantly improve the performance, quality and production costs of lithium-ion cells.

This is to be achieved by developing efficient, resource-saving manufacturing processes and by developing, programming and implementing an effective, comprehensive quality assurance concept along the entire value chain. The ultimate goal is to reduce quality fluctuations, reject rates and costs in the production of lithium-ion cells. An important aspect of this project is the use of the research production facility (FPL) as a scientific reference and integration platform. The results of the various collaborative projects of the “ProZell Competence Cluster” are also to be combined and validated on an industry-oriented battery cell format (PHEV-1).

The QS-Cells project is researching and improving quality-relevant core processes and QS-methods for calendering, post-drying, filling and forming using industry-relevant material examples. The improved processes will be used to produce PHEV1 cells at the research production line (FPL) in Ulm and to evaluate development progress using performance data and tests. Statistical analyses are to be used to identify relevant parameters, develop process models and develop a quality assurance concept. The results should make an important contribution to the development of economical and sustainable battery cell production in Germany.