safety. Automated systems minimise human error, maintaining stringent quality control standards.
Battery cell production is a complex manufacturing process. It involves mixing and coating active materials, precision assembly of electrodes and separators into cells, electrolyte filling and cell sealing and formation cycling. The latter is a time-intensive process where cells are charged and discharged to stabilise chemistry. These steps demand tight process control, which is best achieved through automation, reducing contamination risks and improving throughput.
PC-based control technology is key to precision manufacturing tasks described above. Beckhoff’ s centralised control platform integrates various automation
Battery manufacturing requires high precision, which is where automation excels.
functions, enabling synchronised and efficient management of complex manufacturing tasks. This approach is particularly beneficial in battery cell production, where precision and speed are critical.
Gigafactories aim to produce massive quantities of battery cells, often measured in gigawatthours( GWh) per year. Automation enables continuous, high-speed production lines. It also lowers labour costs and reduces waste through efficient resource use and advanced monitoring of production parameters.
Automation also delivers benefits by improving worker safety. Certain processes involve hazardous materials or high-voltage systems, for example lithium handling or electrode coating. Replacing manual workers with machines ensures safe handling of dangerous materials, protecting workers from exposure.
Automation is also increasingly in demand for its ability to facilitate flexibility and innovation. Automated systems can adapt to different battery chemistries( e. g., NMC, LFP, solid-state) with relative ease, supporting innovation through customisable production lines. Smart factories use sensors and IoT devices to monitor every stage of production, enabling predictive maintenance and real-time optimisation.
There are also the environmental benefits to consider. As a general rule, automation improves resource efficiency by minimising waste and optimising material use. Automated gigafactories also integrate renewable energy systems and smart energy management to reduce the carbon footprint of production.
The automated road ahead
Automation requires significant upfront costs in robotics, software, and training. Operators and maintenance workers need advanced skills to manage automated systems, highlighting the importance of workforce training. The Committee report was right to recommend investment in training and upskilling, as well as financial support.
The Catapult Scheme could be key in helping UK manufacturing embrace automation. The scheme is a network of innovation centres designed to drive the development and commercialisation of new technologies. We recently showcased XPlanar, an intelligent transport system using magnetic levitation technology, at the National Manufacturing Institute in Scotland, a state-of-the-art facility that has received funding through the Catapult Scheme. Technologies like this will play a role in support the automation needs of UK gigafactories.
These centres bridge the gap between academic research and industry, helping to turn ideas into products and services that contribute to economic growth. The programme is overseen by Innovate UK, the government’ s innovation agency. The High-Value Manufacturing Catapult and the UK Battery Industrialisation Centre( UKBIC), part of the scheme, are particularly relevant to the UK’ s efforts in developing gigafactories.
Increasing battery manufacturing capacity to meet future demand and remain competitive in a global market will require a concerted effort from multiple stakeholders in the UK government and economy. If the goal is to be achieved, it will require increased automation in UK manufacturing. Wider adoption of automation technologies, while not automatically solving the gigafactory gap, can surely help steer us in the right direction.
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Issue 74 PECM 61