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Johnson Controls Plans Automated Submodule Manufacturing

Johnson Controls Power Solutions, the world’s leading supplier of automotive car batteries, is planning to manufacture prismatic battery modules in an automated process. This process is expected to increase manufacturing efficiency and reduce costs of the complex technology. Johnson Controls is the first company in the world to produce lithium-ion batteries for mass-production hybrid vehicles.

The benefits of Johnson Control’s next-generation prismatic automotive lithiumion cells and submodules were showcased at MobiliTec – a leading trade fair being held as part of Hannover Messe (April 23 – 27, 2012).

The company’s innovative prismatic modular systems save space, making it easier to adapt to different cars. It also takes less time to develop components for vehicle electrification, reducing production costs. Johnson Controls believes that, by adopting an automated manufacturing process, it will be able to make the technology more affordable, thus supporting mass-adoption of hybrid and electric vehicles.

Submodule Prismatic Cells

Photo: Johnson Controls

An application to build the automated test line is pending under the German national showcase project. If awarded, Johnson Controls plans to build the automated test line to assemble submodules in Hanover, Germany in 2013, after prismatic cells begin production at the company’s facility in Holland, Mich., USA.

“With these modules, we plan to series-produce energy storage devices for use in hybrid, electric and plug-in hybrid vehicles starting in 2014. The lessons we learn and the experience we gather from a pilot facility will help to make the mass production of lithium-ion batteries more efficient,” says Stefan Suckow, Johnson Controls managing director. “With many entries, the selection process will run on until spring. We hope that we’ll be able to get our project off the ground with a view to making safe, high-quality green technologies more costeffective and more appealing to everyone.”

The new prismatic submodules will feature necessary energy storage system components such as the storage cells, an electric collector system, monitoring electronics, a cooling system and mechanical mounting options. The company’s design enables up to 24 submodules to be integrated vertically to form the battery. They are designed so that they will all deliver the same amount of energy, resulting in uniform performance.

Submodule Cylindrical Cells.

Photo: Johnson Controls