Production Line for Aluminium Battery Cell Housings

Fully automatic production of battery cell housings – from raw profile feeding to the ready - to - install component.

Your Challenge

The production of aluminium battery cell housings for e - mobility demands the highest standards: tight tolerances, high volumes and complete traceability are essential. At the same time, production must run economically and with full process reliability – day after day, shift after shift.

Our Solution: One Line – Everything Included

Our fully automatic production line enables the precise, clean and efficient manufacturing of battery cell housings – from raw profile feeding through to the finished component. The system stands out through its high process reliability, short cycle times and fully automated processing.

Main Components of the Line

The production line consists of several precisely coordinated stations that enable a continuous, fully automatic manufacturing process.

At the beginning of the line is the automatic horizontal loading magazine, which handles the bundled feeding and precise alignment of the raw profiles. From there, the profiles are fed to the Profilma 460 high - speed circular saw, which delivers a highly precise, clean and completely oil - free cut – without the use of any coolants or lubricants, achieving a length tolerance of ±0.1 mm.

A linear axis for outfeed transport ensures the automatic transfer of the sawn cell housings and the reliable separation of offcuts and remnants. The components are then transferred to a buffer conveyor with profile - specific carrier system, where they are stored in an orderly manner and passed on to the next station.

At the laser marking station, marking is carried out using two integrated Keyence hybrid lasers. These enable not only precise and permanent marking, but also inline verification of the marking – directly within the process.

Via a linear transfer axis, the cell housings are conveyed to the vertical buffer stations, which handle the separation and loading of the subsequent deburring stations. The automatic double - brush deburring units of the Rasamat Automat type deburr the cell housings on both sides. A dedicated programme ensures the automatic readjustment of the deburring brushes, minimising set - up times, downtime and wear. The control of the Rasamat units is fully integrated into the overall HMI of the line.

At the end of the line is the parts removal table, where the fully processed cell housings are made available for manual or automated further processing. Alternatively, the parts can be automatically removed and fed directly into the next process step.

Production Process

The raw profiles are loaded in bundles into the loading magazine, automatically separated and then fed to the Profilma 460 circular saw automats. The cutting is performed using a special programme developed specifically for battery cell housings, with individually adapted sawing conditions – entirely without the use of coolants or lubricants. The profiles are cut with a length tolerance of ±0.1 mm.

After exiting the sawing chamber, the sawn component is removed from the saw as a cell housing. Lead cuts and remnants are automatically separated out. The clean cell housing is then picked up by a buffer conveyor, where the housings are arranged in profile nests and buffered for transfer to the laser marking station.

Once in position, marking is carried out using two Keyence hybrid lasers. These enable not only precise and permanent marking, but also inline verification of the marking within the process.

After marking, a transfer axis picks up the components and feeds them to two vertical buffers, which supply two Rasamat Automat brush deburring units with two cell housings each. The control system is fully integrated into the overall HMI of the line. A dedicated programme ensures the automatic readjustment of the deburring brushes, minimising set - up times, downtime and wear.

Once both profile ends of the cell housings have been deburred and the components released by the Rasamat units, they are staged for collection – either handed over to a removal device or automatically removed and fed into the next process step.

Performance Data

The production line achieves a maximum daily output of 60,000 battery cell housings at a cycle time of approximately 1.35 seconds per housing. Technical availability is 94%. Raw profiles with a length of 5,000 to 8,500 mm can be processed – longer profiles are available on request. The overall dimensions of the line are approximately 20 × 6 × 5 m (L × D × H).

Processable Cell Housings

The line processes aluminium battery cell housings with a width of 10 to 30 mm, a height of 60 to 130 mm and a length of 200 to 500 mm. Wall thicknesses range from 0.30 to 1.50 mm. The stated dimensions represent a framework of optimal values for production planning purposes. Individual adaptations are of course possible – in such cases, the overall line data may change accordingly. Depending on the configuration and combination of dimensions, not all cell housing variants may be feasible.

Options

The production line can be extended with a range of options: fully automatic profile loading, inline length measurement (mechanical or optical), inline profile cleaning via a profile washing line, automated profile removal and production data logging for complete documentation of your manufacturing process.

Your Benefits at a Glance

Fully automatic – From raw profile to ready - to - install housing without manual intervention

Precise – Length tolerance of ±0.1 mm, entirely without coolants or lubricants

High - performance – Up to 60,000 cell housings per day at 1.35 seconds cycle time

Traceable – Inline laser marking with integrated verification

Process - reliable – 94% technical availability, centralised HMI control

Flexible – Adaptable to various housing formats and profile dimensions

Expandable – Optional modules for cleaning, measurement and data acquisition

Let's Talk About Your Requirements

Are you planning a battery cell housing production line or looking to automate your existing manufacturing? We are happy to advise you – from feasibility analysis to turnkey line delivery.