Festo driving battery production forward

Friday, 21 March 2025

Brian Heslop of Festo explains how collaboration between two leaders in automation technology is enhancing Lithium-ion battery production.

The shift from internal combustion engines (ICEs) to electric vehicles (EVs) is a critical step towards net-zero carbon emissions. However, batteries remain the most expensive EV component and dictate range and performance. To address this, manufacturers are focused on reducing costs while improving battery life, efficiency, and safety.

Achieving these improvements requires a robust, cost-effective supply chain and advanced automation solutions. Faster machinery with higher productivity, precision, and flexibility is essential. To support this, Festo and Siemens have collaborated to enhance the Multi-Carrier System (MCS®), providing solutions for key battery production challenges.

Unlocking Battery Automation Potential

Originally designed for high-end packaging and printing, the MCS® system manages transitions in continuous flow processes. Festo and Siemens recognised that these capabilities could be applied to battery production—from handling active material foils to cell stacking and module assembly.

The MCS® consists of linear motor tracks, customisable carriers, guide systems, and sophisticated drives and controls. The track houses motor windings (stator), generating a magnetic field that moves the carriers with permanent magnet plates. This system allows accelerations up to 50 m/s² and speeds of 4 m/s, making it highly dynamic.

Independent carriers transfer seamlessly between linear motor tracks and traditional conveyors, balancing speed and precision with cost-effective transport. Linear motors provide smooth acceleration, high speeds, and exact positioning, while conveyors offer additional functionality such as buffer stations and curved sections. The result is a flexible, efficient system for battery manufacturers.

Enhancing Performance

Festo and Siemens have expanded the capabilities of the MCS® to maximise benefits for battery manufacturers.

• Increased motor track performance up to 30% – Liquid cooling replaces fan-driven air cooling, boosting speed and power without reducing motor lifespan.
• Higher feed force – More high-energy Neodymium magnets (NdFeB) installed on the underside of the carriers
• Optimised handling – Custom carriers now include vacuum and pressure-driven air clamps.
• Greater precision – Optical encoders replace standard Hall effect encoders, improving resolution from ±0.01mm to ±25µm.
• Full traceability – Individual RFID carrier identification enables seamless data transfer.
• Enhanced flexibility – New track lengths (51mm, 102mm, 204mm, and 306mm) and expanded conveyor options increase adaptability.
• Wide load range – Supports carriers from under 1kg to over 50kg, with twin-track systems for heavier loads.

Optimised Battery Production

The MCS® integrates advanced motion control from Siemens, enabling precise carrier handling. The SIMATIC system synchronises external conveyor drives, manages carrier groups dynamically, and supports advanced camming functions.

Siemens’ SINAMICS S120 system, combined with RAILCTRL Technology Extension, ensures smooth transitions between encoders and MCS® track sections. Engineers can choose from multiple SIMATIC hardware and software solutions in the TIA Portal. Drag-and-drop programming simplifies implementation, and each carrier can be visualised as a separate technology object within the system.

Digital twin capabilities, powered by SIMIT, NX MCD, and the MCS® VC Toolbox, allow manufacturers to simulate and test setups before deployment. This minimises downtime, making multi-location production and later modifications more efficient.