E-Qual – Data-based process and method development to increase efficiency and quality in Li-ion cell production

The project E-Qual focuses on the data-based development of flexible machines, sustainable production processes and innovative quality management methods for battery cell production to minimize cost, increase quality and throughput and improve the ecological impact compared to the state of the art.

Executive Summary:

  • Data-based development of
    • flexible processes and machines
    • models to increase material and energy efficiency
    • innovative quality assurance methods
  • Improved management of energy and resources
  • Comprehensive quality management concept


  • Minimizing cost
  • Enhancing quality and throughput
  • Improving the ecological impact

Project Details:

The E-Qual project aims to increase efficiency and quality in the production of lithium-ion batteries. Using data-based approaches, the four partnering institutes develop and implement solutions to minimize costs and environmental impacts as well as measures to increase quality, energy density and throughput in the field of battery cell construction. The validation of the project results is based on the production of large-format cells in the PHEV1 (plug-in hybrid electric vehicle) format on an industrial scale at the Research Production Line (FPL) in Ulm.

The focus is particularly on the development of flexible processes and machines, the modeling to increase material and energy efficiency, and innovative quality assurance methods. Already established cell assembly processes are developed and optimized in this project with regard to their flexibility, quality and efficiency. The creation of virtual process models allows the derivation of optimal process and machine parameters and the implementation and validation of newly developed machine components.

A special emphasis lies on the implementation of a function-integrated process for the production of format-flexible cells, which is optimized for minimum set-up time. To realize hidden efficiency potentials in cell production, methods for increasing resource efficiency are applied to the production lines of the participating research partners. This also includes the establishment of automated data acquisition and processing as well as the development of dynamic material and energy flow models. Since the increase of product quality and the reduction of scraps are essential drivers for efficiency increases, integrated quality management concepts for a varied production are being considered. The application of Big Data methods for quality forecasting and early rejection detection, as well as the investigation of the influence of energy efficiency / flexibility measures on product quality, will deliver innovative contributions to an improved quality management.


The iwb would like to thank the Federal Ministry of Education and Research (BMBF) and the Project Management Organisation Jülich for funding this research project.

Duration: March 01, 2020 – February 28, 2023
Funded by: Federal Ministry of Education and Research (BMBF)
Project Partners:
  • Center for Solar Energy and Hydrogen Research Baden-Württemberg (ZSW) (consortium leader)
  • Fraunhofer Institute for Surface Engineering and Thin Films (IST)
  • wbk Institute of Production Science at KIT
Grant Reference: 03XP0252D