Electric Car Battery Line – Dräxlmaier Thailand
Support in the commissioning of automated production workstations for a global manufacturer of automotive components.
Client
DRÄXLMAIER Thailand
Scope of cooperation
PLC programming, commissioning, virtual start-up
Implementation period
2019
Project languages
English
About the project
In 2019, in cooperation with a German engineering firm, Amister participated in a key project to build a modern production line for batteries for electric vehicles. The project was carried out for DRÄXLMAIER in Thailand, a global supplier of automotive components. Our objective was to ensure the flawless commissioning of advanced automated stations necessary for the production of battery components that form the foundation for the growing electric vehicle industry.
Scope of work
Our involvement in the project included PLC programming and support in commissioning key stations on the production line. We carried out comprehensive tasks in the field of automation, with particular emphasis on preparing the structural elements of the battery pack and integrating the processes for preparing battery cells.
Key elements of the scope
1) Automation of the Tension Rods workstation
Commissioning of an automated workstation for the precise preparation of “tension rods” components, crucial to the structure of the battery pack. The process included laser surface cleaning using TRUMPF TruMicro technology and the HELIOS system, and adhesive application using an SCA/Atlas Copco system, integrated with mass measurement on a Mettler-Toledo scale for quality control.
2) Support in commissioning battery cell stations
Assistance in commissioning two workstations responsible for preparing battery cells. Programming tasks included implementing and optimizing processes such as plasma cleaning, precise application of protective films and labels, as well as voltage testing of the cells, ensuring their readiness for subsequent assembly stages.
3) Virtual commissioning
Active participation in the virtual commissioning phase, where each machine was modeled in a 3D simulation environment. This allowed comprehensive testing of all functions and process sequences offline, which significantly shortened and optimized the commissioning phase at the end customer’s site.
Project challenges
The main challenge of the project was to ensure maximum efficiency and shorten the start-up time of a complex production line, while simultaneously maintaining the highest standards of precision required in the manufacture of electric vehicle batteries. The global nature of the project also required efficient coordination among multiple partners and technologies.
Main challenges
Technologies and solutions used in the project
| PLC Programming | Siemens (including TIA Portal controller programming) |
| Laser cleaning | TRUMPF TruMicro, HELIOS system |
| Application of glue | SCA / Atlas Copco |
| Measurement of mass | Mettler-Toledo scale |
| Simulation | 3D environment for virtual start-up |
Effects and benefits for the client
Most important results
• Smooth start-up of the workstation for preparing “tension rods” with precise adhesive application and mass control.
• Effective implementation and optimization of battery cell preparation processes, including plasma cleaning and voltage testing.
• Significant reduction of on-site start-up time at the customer’s site thanks to virtual commissioning.
• Ensuring high quality and repeatability of production processes compliant with automotive industry standards.
• Support in the timely implementation of a project of global significance for the automotive industry.
Added value for the DRÄXLMAIER factory
Thanks to our commitment and the application of innovative methods, such as virtual commissioning, the client gained not only a smoothly operating production line but also significantly reduced the risk of delays and costs associated with the start-up phase. We ensured process stability and high component quality, which translated into increased production efficiency and a competitive advantage in the rapidly developing electric vehicle sector. It is also an example of our ability to work on complex, international projects within robotization of production.
Why do clients choose us for projects?
Amister stands out in projects of international scope thanks to specialist knowledge in PLC programming and experience in advanced technological processes. Our ability to work effectively in complex multi-partner environments, combined with an innovative approach to virtual commissioning, has enabled us to minimize risk and maximize efficiency. We deliver precise solutions that guarantee the successful start-up of even the most demanding production lines, minimizing risk and implementation time.
Summary
The project to build an electric vehicle battery line for DRÄXLMAIER in Thailand, carried out in cooperation with an engineering firm, is proof of our ability to implement advanced industrial automation projects in a global environment. Thanks to our expertise in PLC programming and virtual commissioning, we successfully contributed to the start-up of key production stations, providing the client with high quality and timeliness essential in the dynamic automotive industry.
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During a conversation or correspondence we will jointly define the scope of the work and services you are interested in. Then we will carry out an internal analysis of your inquiry in order to prepare the best possible solution.
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