A technological analysis and prototype design for efficient and flexible stacking processes

The stacking process is a critical bottleneck in EV battery manufacturing with requirements for throughput, quality, and flexibility, especially with the increase of e-mobility and transition to solid-state batteries. This paper presents the analysis of the stacking process from a technological perspective to address industrial challenges and to support the development of more efficient and adaptable manufacturing solutions. Grounded on a solid literature review, the first outcome of the project is the design of a stacking prototype, developed in alignment with industrial targets. The prototype not only serves as a basis for improving current stacking process performance but also provides a platform for future research into key aspects. Central to this work is the investigation for the relationships between key parameters and stacking performances under sub-processes such as gripper speed, suction force, and motion trajectory etc. to enable fast, continuous stacking operations.