EV battery module cell —
cycle-tuned, zero-damage.
Controls optimization and multi-brand robot integration on EV battery module assembly cells at Samsung SDI in Michigan. Mitsubishi iQ-R logic refinement, GOT2000 diagnostics and Korea-side engineering coordination — module cycle cut 35% with ±0.05 mm placement and zero cell-damage events through ramp.
Five issues converging on the cell.
The line was producing, but cycle time was over takt, diagnosis was slow and cell-handling spec left no margin. Each issue had a different owner — the controls scope had to consolidate them under one signed package.
Cycle-time pressure
EV demand outpaced line capacity. Module cycle was over takt and idle waits accumulated across hundreds of cycles per shift.
Multi-vendor cell stack
Mitsubishi iQ-R PLCs, multiple robot brands, vision and GOT HMIs had to interoperate cleanly with the Korea engineering systems.
Diagnostic blindness
When a cell faulted, operators and maintenance lacked clear cause attribution. Fault-to-fix took shifts, not minutes.
Sub-millimetric handling
Cell placement spec was ±0.05 mm with zero tolerance for mechanical damage on pouch and prismatic cells.
Korea-spec compliance
All changes had to pass Samsung SDI's global engineering review under their template, naming and validation gates.
Module assembly — top-view layout.
Schematic of the EV battery module cell: cell magazine, vision check, dual robot pick / place into the module fixture, ESD-grounded conveyor and CC-Link IE bus to the iQ-R PLC and GOT2000 HMI.
Cell optimization as one package.
PLC, robots, HMI and global engineering coordination delivered in one execution stream.
Mitsubishi PLC optimization
Full audit of the iQ-R logic powering module-assembly cells, focused on where cycle-time was actually lost.
- ▸Eliminated redundant logic + dead branches
- ▸Re-sequenced robot ↔ PLC handshakes
- ▸Tightened interlock timing without loosening safety
- ▸Refined error handling for fast, safe recovery
Multi-brand robot integration
Brought the multi-vendor robot fleet into a coherent, cycle-tuned cell.
- ▸Robot ↔ PLC comms hardened over CC-Link IE
- ▸Pick / place paths tuned for ±0.05 mm placement
- ▸Collision envelopes verified per pose
- ▸Per-cell cycle-time decomposition and retune
GOT2000 HMI development
Operator and maintenance screens rebuilt around fast diagnosis instead of raw I/O.
- ▸Real-time cell tracking + pose visualization
- ▸Fault screens with attributed root cause
- ▸Production / OEE dashboards per shift
- ▸PM alerts + preventive scheduling
Global engineering coordination
Ran the project against Samsung SDI's Korea-side engineering org as a single pipeline.
- ▸Daily Korea ↔ US engineering syncs
- ▸Documentation per Samsung SDI templates
- ▸Validation through Samsung's approval gates
- ▸Remote-monitoring integration support
Cell specification — as released.
Process and control parameters under SAT-validated release.
From audit to SAT release.
Five phases with measurable engineering deliverables.
Cell + cycle audit
PLC + HMI redesign plan
Robot + PLC tuning
Placement + damage study
Samsung SAT + handover
Performance validated through ramp.
Measured outcomes from startup and stabilization.
- Module cycle time cut 35 % at constant safety
- Zero cell-damage events through ramp
- Placement accuracy held inside ±0.05 mm
- Fault-to-fix time down 40 % via GOT2000 diagnostics
- Daily output moved from below to above takt
"iAutomate consolidated PLC, robot and HMI under one signed package and aligned with our Korea engineering team. The cell hit takt and held it."
BATTERY MFG ENGINEERING · SAMSUNG SDI
What we delivered.
Adjacent signed deliveries.
Need to stabilize an EV cell
without sacrificing quality?
If your battery line is over takt or diagnostics are too slow, we can execute a cycle + quality recovery plan.