Precise sensor solutions for E-mobility.

Efficient and safe production at BMW Plant.

Leuze sensors perform important tasks in the cell coating line and module production at the BMW Group plant in Leipzig: They reliably detect objects and also meet high requirements, such as the detection of high-gloss surfaces. In addition, safety technology from Leuze ensures seamless safety on machines and systems. The Sensor People thus contribute to efficient processes in the automotive industry and are always on hand to support system operators in the design and implementation of sensor and safety solutions.

The site  produces both combustion engine and electric models in parallel. E-mobility requires high-voltage batteries to supply the BMW Group's electric cars or hybrid vehicles with the necessary drive energy. The automotive group also manufactures these on site. Sensor technology from Leuze makes an important contribution to an efficient and safe production line process, implemented by Schaeffler Special Machinery, the Schaeffler Group’s mechanical engineering company.

It all starts with the cell.
Three successive production steps are required from the first component to the finished high-voltage battery. Only after cell coating, module production and finally assembly is a high-voltage battery ready for use as an electric vehicle’s energy supply. Precision and reliable processes are essential at every step. Leuze supports this with sensor solutions in cell coating and module production. Cell coating is the first step in high-voltage battery production. Each battery module consists of several cells. These are delivered to BMW in large load carriers (GLT). So that the GLTs can be unloaded automatically by robot, a Leuze MLC safety light curtain secures the danger zone to prevent people from entering. Muting ensures that only the GLT can pass through. The robot always unloads 16 cells at the same time and places them on a conveyor belt. Here, horizontally installed, Leuze CSL switching light curtains detect whether the cells are positioned correctly. “The switching light curtains particularly suitable for monitoring large detection fields as they are easy to install, configure and far more cost effective than image-based systems” explains Jürgen Schweiß, KAM-Automotive and Safety Application Specialist at Leuze.

High-gloss surfaces.
Diffuse sensors from Leuze are implemented at different points: “Sensors mounted on the belt detect the presence and correct position of the cells. If they are present and correctly positioned, the process continues,” says Jürgen Schweiß. The advantage of the PRK 25C series sensors used here is that they can detect the high-gloss surface of the cells with absolute reliability and can installed even in confined spaces due to their small physical size. Despite its small size the sensor has an operating range of 16 meters. Another advantage is that the sensors can be easily adjusted for sensitivity and alignment due to their bright light spot.

A compact approach to safety.
Sensor technology from Leuze keeps an eye on every aspect of cell coating: Laser diffuse reflection sensors from the HT46CL series detect the individual cells and control the conveyor – with maximum detection reliability thanks to background suppression. Before the cells are loaded into a GLT, they are discharged through a Leuze MLC safety light curtain. Advantages of Leuze light curtains: They not only score points with their high resolution, protective field height and operating range, as Jürgen Schweiß emphasizes: “With light curtains, a compact design and short safety distances are also important. This allows them to be easily integrated into tight installation situations.”

Perfectly positioned.
Leuze laser diffuse reflection light scanners also monitor the unloading of the cells from a GLT into a module line from Thyssenkrupp Automation Engineering. Each cell also receives a “heat shield” – a protective heat insulation – which is pressed onto the long sides. Robots rotate the cells into the desired position on a circular machine. Sensors from Leuze also provide support here: PRK 25 retro-reflective photoelectric sensors detect the presence of the objects. The heat shield process runs in parallel at two stations in order to achieve a high throughput time.

From stacking to the module.
In “stacking”, as experts call the stacking of several cells to form a battery module, several cells are placed next to each other and a pressure plate is attached to each end. PRK 25C sensors from Leuze detect the height and presence of the cells and recognize whether the tool carriers are closed correctly. Sensors are also used when placing the cell contact system (ZKS) on the module. A machine lifts the entire module so that the coating on the cell base can be checked: “Here, Leuze sensors provide support for height detection and at stop positions” says Schweiß.

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Light curtains

The GL-R Series is the most robust of the market thanks to a metal housing 3 times thicker than the traditional safety curtains (32x38 mm). This new series has been designed to address the problems users are having with safety light curtains. Unique and strong design, quick and easy installation, and yet the highest level of security is provided.

Another unique feature: its thick and robust metal built-in guard protects the lenses (5 mm recess). Thus, the probability of direct impacts on this sensitive part is extremely reduced. Finally, the GL-R Series housing meets IP65/IP67 enclosure ratings. The system offers significant advantages for the user: downtime risks are reduced, no need of expensive additional guarding and finally twisting and misalignment issues are eradicated thanks to the robust design.

These curtains are much easier to install. With the one-line system, no need to connect the transmitter and the receiver to the control panel, because the transmitter receives power from the receiver. Moreover, with the optical synchronisation, the transmitter and receiver can be wired separately. The number of wires is reduced by 72% from 18 to 5 wires, thus reducing installation time and risks of faulty wiring.

Assembly is also simplified: the GL-R Series brackets come pre-assembled, so installation is as simple as sliding them into the mounting track and securing them to the machine.
These mounting brackets have been designed to attach directly to standard extruded aluminum allowing a straight or L-shaped or adjustable angle mounting. The range of detection has been increased up to 15m. On top of these features the GL-R series curtains do not require any additional protection making this system the simplest to install in the industry.

The GL-R series meets the machine safety design standard ISO 13849-1, PLe level of performance. It is the most demanding: Mean time to dangerous failure per hour: 10-8 to < 10-7.
These curtains are also Type 4 and SIL3.

This Series, in keeping with the other Keyence safety light curtains, offers a no dead zone detection, with the first beam emitted 10 mm from each end. There is no need for additional guarding to prevent intrusion on the dead zone detection level.
Many curtains still do not offer this key safety feature. Compared to the models allowing edge detection, the GL-R Series solves the common problem of end brittleness.

Finally, with the 7 segments display errors are more easily and safely identified.
Last innovation, the operation of the GL-R Series can be monitored with a PC. The status of I/O signals including OSSD outputs, override inputs, and error conditions can be checked as well as light intensity. During operation, the monitoring will help to easily identify the causes of an abnormal operation. All error codes and order of occurrence are saved as error history records during operation. This allows for easiertroubleshooting and analysis.