Enabling the Electric Future of Mobility: Robotic Automation for Electric Vehicle Battery Assembly

Abstract

Consumer demand for Electric Vehicles (EVs) is increasing due to improving performance and affordability. However, EV manufacturers are struggling to meet this rise in demand. A key bottleneck is supply from a nascent EV battery supply chain that is new and developing. In this paper, we propose robotic work cell design for fast and reliable assembly of EV battery modules, at scale, to reduce this demand-supply gap. INDEX TERMS Automation, digital simulation, digital twin, electric vehicles, EV batteries, industrial robots, lithium ion batteries, robots, robotic assembly. I. INTRODUCTION A. EV DEMAND IS UP Even though electric vehicles(EVs) account for only a small percentage of all vehicle sales today, there has been a steady and sharp increase in consumer adoption. According to the 2018 IEA Global Electric Vehicle Outlook, new registrations of EVs increased from 111,320 in 2013 to 750,490 in 2017, a 575 percent increase [1]. A 2018 survey by AAA found that consumer interest in electric vehicles is increasing, with 20 percent or 50 million Americans likely to go electric for their next vehicle purchase, up from 15 percent in 2017 [2]. This increase in acceptance has been supported in part by incentives for the adoption of electric vehicles in several countries. These incentives coupled with the dramatic fall in battery prices (Fig. 1) and increase in driving range per charge, has resulted in increasing acceptance of EVs by consumers, as reflected in their rising demand (Fig. 2).

Analysis of the Li-ion battery industry in light of the global transition to electric passenger light duty vehicles until 2050

“…However, concerns about the supply failing to meet the demand are already becoming prevalent. Recently, several automotive manufacturers stated that production delays are due to production bottlenecks in the pack assembly [58]. If the EV demand keeps growing at the rate observed in the past 5 years it is likely that other original equipment manufacturers, as they move to a larger portfolio of EVs available, may face similar issues.…”

“…Our analysis assumed an average of 120 employees/GWh, which is the average value reported [51,[55][56][57]. However, LIB production holds potential for the automation of some production steps [58]. Therefore, the future employment generated may be lowered by automation and industry 4.0 trends, following the forecasts for the automotive sector as a whole [59,60].…”

A Computer Science Perspective on Digital Transformation in Production

“…Some of these improvements can be implemented automatically, especially since the concepts originating from the broader context of IIoT, Industry 4.0, and the IoP enable wide-spread factory automation and reconfiguration [149]. Yet, uncalled-for automation limits the optimization of production and processes [137], which is why the impact of human workers should not be underestimated. Access to IoP-Enabled Knowledge.…”

Towards robotizing the processes of testing lithium-ion batteries

“…3 To capitalise on this rising; reuse, recycling and recovery of those batteries is getting imperative to support the circular economy and diminishing ecological harm. 4 This demand grading the retired batteries according to their current state of health (SoH) for reusing in the primary or secondary application and acquiring an exhaustive knowledge about the degradation mode before recycling after the end of second life.…”