Transforming battery manufacturing processes

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July 2025 IT in Manufacturing

Siemens and Hirano Tecseed, a Japanese machine builder, are partnering to transform battery manufacturing processes. The collaboration focuses on the standardisation and digitalisation of battery coating machines to optimise coating processes, reduce waste and enhance product quality and operator performance.

The battery market is rapidly expanding due to the global shift toward sustainable energy with the growing importance of electric vehicles and utility-scale energy storage. Hirano and other machine builders are looking to increase battery production and reduce their costs while maintaining high levels of quality and safety. A crucial production step involves coating foil strips with multiple active layers to form the battery electrodes. Any defects in this process can negatively affect the performance and durability of the finished battery. Close monitoring and control of speed and tension during the coating process are essential.

A key component of the collaboration has been the development of a digital twin for battery manufacturing equipment. Using Siemens’ Simcenter software, Hirano successfully simulated and tested a digital twin of its battery coating machine. Drawing on real-time data from a Simatic controller and Sinamics drives, which automate the pilot machine, the simulation provides a highly accurate virtual model for performance testing. By leveraging Simcenter Amesim, a systems simulation software from the Siemens Xcelerator platform, Hirano’s design engineers can virtually assess and optimise the machine’s web handling system for maximum throughput.

In the past, parameters for Hirano’s machines were set based on experience, which could lead to defective products due to incorrect settings. Using Siemens’ comprehensive digital twin technology has enabled Hirano to configure and simulate a machine in a virtual environment before committing to physical production. This allows Hirano to reduce the need for physical prototypes significantly and predict potential product defects. Development engineers can evaluate and optimise machine settings five times faster in the virtual environment compared to physical operation. Additionally, up to 80% of the machine simulation and digital twin can be constructed using pre-configured, standard function blocks, resulting in shorter implementation and commissioning times and a reduction in development costs.

“We’re thrilled to collaborate with Siemens to enhance our battery manufacturing processes,” said Katsuhiro Omori, director and executive officer of R&D; at Hirano Tecseed. “Integrating mechatronics and automation simulation systems into a unified modelling environment has significantly helped Hirano identify potential product defects and advance our machine process optimisation in a virtual setting.”

“By leveraging our advanced simulation and automation technologies, Siemens is enabling Hirano to achieve unprecedented levels of efficiency and quality in battery manufacturing,” added Michael Thomas, senior vice president of Factory Automation and head of Production Machines at Siemens. “This partnership exemplifies our commitment to driving innovation and supporting our customers in their digital transformation journey.”

For more information contact Siemens South Africa, [email protected], www.siemens.co.za

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IT in Manufacturing

Transforming battery manufacturing processes

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