QUALITY CONTROL SYSTEM IN

BATTERY MANUFACTURING
Tube Investments of India Limited

AUGUST 16, 2020

KISHORE S
Indian Institute of Management Visakhapatnam
 QUALITY CONTROL SYSTEM IN BATTERY MANUFACTURING

TABLE OF CONCEPTS:

1. INTRODUCTION: 2

1.1. BATTERY: 2
1.2. TYPES OF BATTERY: 3

2. MARKET OVERVIEW OF BATTERY MARKET BY MORDOR INTELLIGENCE: 5

2.1. MAJOR MARKET DEVELOPMENTS: 5

3. LITHIUM-ION BATTERY PRODUCTION PROCESS: 8

3.1.ELECTRODE MANUFACTURING: 8
3.2. CELL ASSEMBLY: 12
3.3. CELL FINISHING: 17

4. QUALITY CHECK: 21

4.1. NEED FOR QUALITY CHECK: 21

4.2. INTEGRATING THE ASSEMBLY LINE AND QUALITY ASSESSMENT PROCESS: 21

5. CONCLUSION: 26

6. LEARNINGS: 27

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 QUALITY CONTROL SYSTEM IN BATTERY MANUFACTURING

1. Introduction:

1.1. Battery:
The battery is a device which consists of one or more electrochemical cell with external
connections to provide power to other devices. The battery supplies electricity to extended
applications like flashlights, mobiles, remote devices, electric vehicles, etc.,

A battery operates on the oxidation and reduction reaction of an electrolyte with metals. Two
different metallic substances, called an electrode, are arranged in a diluted electrolyte,
oxidation, and reduction effect take place in the electrodes, varying upon the electron affinity
of the metallic electrodes. As a result of the oxidation reaction, one electrode gets negatively
charged called cathode, and due to the reduction reaction, another electrode gets positively
charged called anode. This difference in electron concentration causes an electrical potential
difference developed between the metals. This electrical potential difference or emf can be
utilized as a source of voltage in any electronics or electrical circuit.

Fig 1.1.1: Working Principle of a Battery

Source: engineersgarage

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1.2. Types of Battery:

Batteries are classified into two types:

• Non-rechargeable batteries (primary batteries)

• Rechargeable batteries (secondary batteries)

Primary batteries:

Primary batteries can be used only once. These batteries can't be recharged and utilized
again. It has two main types,

• Alkaline batteries
• Coin cell batteries

Advantages:

• Cycle life is more

• More compatible and efficient for powering up portable devices.
• Shelf life is more
• Small in size
• Highly efficient
• Low internal resistance, so that the discharge state in idle state is less
• Leakage is low

Secondary batteries:

Secondary batteries are recharged and reused. The cost is high, but they can be recharged
and reused and can have a vast life span when properly used and safely charged. Some of the
standard secondary batteries are as follows,

• Lead-acid batteries
• Ni-Cd batteries
• Ni-MH batteries
• Li-ion batteries
• Li-Po batteries

Advantages:

• High power density

• Easy to recharge
• Cell voltage is high

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Fig 1.2.1: Types of Battery

Source: Components101

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2. Market Overview of Battery Market by Mordor Intelligence:

The battery market is anticipated to increase at a CAGR of more than 12.31% during the
predicted interval of 2020 – 2025. Major influences driving the market involve declining
lithium-ion battery prices, fast adoption of electric vehicles, and enhanced sale of consumer
electronics. The demand-supply gap of raw materials is likely to hamper the market
expansion.

The automotive batteries sector is likely to be the fastest-growing segment for the battery
marketplace, and it is supposed to be leading for lithium-ion batteries in upcoming years.

People devoid of electricity in the African area is expected to surge from 588 million in 2016
to about 602 million in 2030, boosting electrification via grid connectivity. The Sub-Saharan
region is expected to be one of the crucial for off-grid solar connectivity

North America and Asia-Pacific are the local hotspots for the battery marketplace, with
nations like the United States, India, and China impacting its growth.

2.1. Major Market Developments:

Automotive Batteries sector set to be the Fastest-Growing Sector:

The automotive segment is likely to be one of the most important end-user segments for
lithium-ion batteries soon. The access of electric vehicles is expected to provide a substantial
momentum for the lithium-ion battery manufacturing growth.

A variety of distinct vehicle types is available worldwide, ever-increasing levels of

hybridization and electrification. There are a variety of vehicles, involving hybrid electric
vehicles (HEVs), plug-in mix electric vehicles, and electric vehicles (EVs).

In developed and developing countries, the acceptance of electric vehicles is expanding at a

soaring growth rate. The United States and China are foremost in EV sales, with other
developing nations like India, which has already begun changing its public transport
infrastructure for EVs.

In the recent market scenario, policy endorsement plays a key role in guiding the
implementation of electric vehicles. Policy support allows market growth by creating vehicles

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attractive to consumers, decreasing risks for shareholders, and helping manufacturers to

develop electric vehicles on a larger scale.

Declining battery costs and advancing technology are supposed to bring price-driven electric
vehicles to the market, generating demand for battery technologies.

Fig 2.1.1: Battery Market Share

Asia-Pacific Driving the Market Demand:

Asia-Pacific has many rising economies with sizeable environmental as well as anthropological
resources, with China and India probable to be chief investment hotspots for battery firms in
the approaching ages, on account of policy-level provision, from the administrations, inspiring
the industrial sector.

The consumption of electric vehicles and the setting up of renewable energy plants in China
and India is expanding quickly, which is supposed to bring up the huge need for batteries.

China is presently one of the biggest markets for the electric vehicle and has reached 30 times
quicker progress than the electric vehicle marketplace in 2018 when related to 2017.

The rising adoption of electric vehicles is in line with the clean energy policy. The
administration of China is preparing to ease constraints on automakers introducing cars into
the country to lower the demand-supply gap.

Asia-Pacific is probable to be the leading performer in the battery marketplace. It is reinforced

by growing development and consumer expenditure across numerous countries, like India
and China, which is likely to improve the requirement for technically innovative devices &

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automobiles, due to the aids offered by the same. Successively, leading to a development in
demand for batteries.

Fig 2.1.2: Battery Market Share by Region

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3. Lithium-ion Battery production Process:

The manufacturing of the lithium-ion battery cell involves three major processes,

• electrode manufacturing
• cell assembly
• cell finishing

3.1.Electrode Manufacturing:
Irrespective of the cell type, the tiniest unit of any lithium-ion cell comprises two electrodes
and a separator, which divides the conductors from each other. The ion-conductive
electrolyte fills up the minute opening of the electrodes and the residual space inside the cell.

Fig 3.1.1. Cell Structure and Cell design:

Mixing:

With the support of a rotational tool, at least two distinct raw materials are blended to form
a so-called slurry. The manufacture of slurry needs not only functional raw material but also
conductive extracts, diluters, and binders. A difference is made between mixing (dry mixing)
and dispersing (wet mixing). Besides, the method can be done under vacuum to prevent gas
presence. The selection of the mixing and dissolving order must be modified to the electrode
design to be produced.

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Fig 3.1.2. Mixing:

Coating:

The foil is covered with the slurry using an appliance tool (e.g., slot die, doctor blade, anilox
roller). The foil is covered either constantly or intermittently in the coating way. The top and
bottom sections of the foil are coated in sequence. The coated foil is steadily moved to the
dryer. After the first drying process, the foil-covered on one side is fed back to the coating
system by a manual transfer process. Afterward, the second side is coated according to the
process described.

Fig 3.1.3. Coating:

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Drying:

After coating, the employed active raw material is dried up in a constant process. The solvent
is eliminated from the raw material by high-temperature supply. The extremely flammable
solvent included in the cathode coating is retrieved or used for thermal reprocessing. The
transportation of the foil is done either by roller techniques or by floatation air flows. For an
instantaneous, dual-sided coat, the floatation dryer must be utilized. The dryer is separated
into different temperature zones to get an individual temperature report. A chamber system
typically achieves this. After passing on through the dryer, the foil is chilled along to room
temperature and, dependent on the form of system, reversed or directly coated on the
second side.

Fig 3.1.4. Drying:

Calendering:

Through calendering, the copper or aluminum foil covered on both sides is squeezed by a
rotational pair of rollers. The electrode foil is initial statically released and washed by brushes
or airflow. The top and bottom rollers compress the raw material. The pair off of rollers
creates an accurately well-defined line force. After calendering, the electrode foil is cleansed
and rolled up again.

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Fig 3.1.5. Calendering:

Slitting:

The calendered rolls are generally fed to the cutting base by a manual transport method.
Slitting is a partition process in which a wide-ranging electrode coil is separated into
numerous lesser electrode coils. Generally, rolling blades are utilized for this reason. The
special daughter rolls are washed and reversed after the cut off procedure.

Fig 3.1.6. Slitting:

Vacuum Drying:

The covered daughter rolls are pressed onto a unique goods delivery service. The coils are
then put in storage in a vacuum oven. The drying time is approx—12 h to 30 h. During the
drying procedure, remaining humidity and solvents are deleted from the coils. The cut of
remaining moisture is accomplished by evaporation at low heats as a result of low overall

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pressure. After vacuum drying has been finished, the coils are transmitted directly to the dry
chamber or dry filled under vacuum.

Fig 3.1.7. Vacuum Drying:

3.2. Cell Assembly:

Separation:
Separation is necessary for the creation of the pouch cell and explains the partition of the
anode, cathode, and filter sheets from the roll stuff. The dried daughter rolls are loosened
and supplied to the partition tool. The cutting process mostly takes place with a shear cut in
an uninterrupted process. Dependent on the system idea, the specific sheets are kept in a
journal or shifted directly to the next method step.

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Fig 3.2.1. Separation:

Stacking:

Through the stacking process, the divided electrode sheets are stacked in a replicating series
of the anode, separator, cathode, separator, etc. A large variety of piling technologies exists,
which are frequently patented by specific manufacturers. A typical variant of piling is the so-
called Z-folding. The anode and cathode sheets are introduced interchangeably from the left
and right into the z-shaped crinkled separator. The filter is used in the form of an infinite tape
and is cut off after the piling process. The cell pack is finally fixed with adhesive tape.

Fig 3.2.2. Stacking:

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Packaging:

To pack the pouch cell, the modern gatherer foils (anode - copper and cathode - aluminum)
are first communicated with the cell tabs utilizing an ultrasonic or laser soldering process. The
cell stack is then placed in the pouch foil. For this reason, the pouch foil is intense-drawn in a
previous process step. The pouch cell is sealed gas-tight on three sides in instinct or make
contact sealing process. One side of the cell is not completely sealed in request to be able to
load the battery cell with electrolyte in the later process.

Fig 3.2.3. Packaging:

Electrolyte Filling:

Next, To the packaging method, the electrolyte is covered. Electrolyte sealing, a difference
must be made between the secondary-methods "filling" and "wetting." The electrolyte is
loaded into the cell under vacuum with the assist of a superior-precision dose up a needle. By
utilizing a stress report to the cell, the capillary impact in the cell is generated. Removal and
partial filling are duplicated numerous times, dependent on the producer and cell type. Lastly,
the pouch foil is closed under vacuum.

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Fig 3.2.4. Electrolyte Filling:

Winding:

Winding is needed for the manufacture of prismatic cells and cylindrical cells and gets set
following the vacuum drying of the daughter rolls. The electrode foils and two filter foils are
rolled all-around a rolling mandrel. The foil cycle is similar to the stacking process. An adhesive
strip finally obtains the placing of the specific foils of the Jelly Roll.

Fig 3.2.5. Winding:

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Packaging:

In contrast to the cell pile in the pouch cell, the jelly roll is introduced into a tough metal
frame. In the prismatic cell, the boundaries of the jelly roll are squeezed, installed, and
ultrasonically connected to the link terminals fastened to the cover of the battery. An
insulation foil keeps the jelly roll through incorporation into the prismatic housing. The
housing is normally closed by a laser fusing process. The initial step in the cylindrical cell
method is to add a bottom padding, and the jelly rolls into the circular frame. Then, the
current collector of the anode is mostly fused to the bottom of the frame, and the existing
collector of the cathode is connected to the lid. Finally, a protection ring is created between
the jelly roll and the lid.

Fig 3.2.6. Packaging:

Electrolyte Filling:

The electrolyte filling requires place after the jelly roll has been injected into the housing.
During electrolyte filling, a difference must be produced in the middle of the sub-processes
"filling" and "wetting." The electrolyte is loaded into the cell in a vacuum with the assistance
of a high-precision dosing needle. By directing a pressure report to the cell, the capillary effect
in the cell is started. Evacuation and partial filling are duplicated many times, varying on the
manufacturer and cell type. Later the cells are sealed.

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Fig 3.2.7. Electrolyte Filling:

3.3. Cell Finishing:

Roll Pressing:
Following electrolyte filling, an elective roll pressing procedure can take up for the pouch cell.
The lithium-ion pouch cell is fixed in a nice unique delivery service with the aid of a gripper. A
servo motor directs the cell all through two rollers that employ well-defined stress. The rollers
are washed in the time being by washing rollers. Roll pressing confirms optimal delivery and
inclusion of the electrolyte under specified stress. This stage provides the groundwork for the
successive creation because the pressurization prevents electrochemically weak areas.

Fig 3.3.1. Roll Pressing:

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Formation:

The formation explains the first charging and discharging methods of the battery cell. For
formation, the cells are placed in good quality leading carriers data packs and make contact
by spring-loaded contact stick pin. The cells are then charged or discharged corresponding to
exactly specified current and voltage movements. In formation, lithium ions are inserted in
the crystal form of the graphite on the anode on the side. The Solid Electrolyte Interface (SEI)
is created, which generates an interface level between the electrolyte and the electrode.

Fig 3.3.2. Formation:

Degassing:

With lots of pouch cells, there is solid progress of gas during the initial charging process.
Pressurized great carriers are demanding this gas out of the cell into a dead space. During
degassing, the gas bag is penetrated in a vacuum chamber, and the leaking gases are pulled
out. The cell is then completely sealed under a vacuum. The gas bag is divided and settled off
as harmful waste away. Last folding and, if needed, sticking of the seal borders to decrease
the outer sizes of the pouch cell can be conducted as an option.

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Fig 3.3.3. Degassing:

Aging:

Aging is the last step in cell manufacturing and is utilized for quality reassurance. In aging, cell
qualities and cell performance are examined by frequently gauging the open-circuit voltage
(OCV) of the cell over up to three calendar weeks. A difference is rendered between high
temperature (HT) and normal temperature (NT) aging. The cells generally first go through HT
aging and then NT aging. The cells are stockpiled in so-called aging shelves and towers. No
substantial variation in the cell properties over the full time implies that the cell is operational
and can be distributed to the customer.

Fig 3.3.4. Aging:

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EOL Testing:

Before the cells depart the factory, they are assessed in an EOL test rig. The cells are
eliminated from the right carriers in the aging packs and fed to the scanning station. They are
released to the distribution state of charge. Depends on the firm, pulse tests, internal
resistance proportions (DC), optical assessments, OCV checks, and leakage examinations are
taken. After analyzing, several cell manufacturers sort the cells corresponding to their
performing data. Once the checks have been finished and approved successfully, the cells can
be loaded and dispatched.

Fig 3.3.5. EOL Testing:

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4. Quality Check:
4.1. Need for quality check:
As per various industrial reports, the rejections rate in quality check is around 15% - 18% of
the total production before the quality checks. These defects not only increase the cost for
the firm but also decrease the efficiency and affect productivity.

In Electric vehicle, cost battery cost nearly 50% of the total cost. The demand for an electric
vehicle is rising exponentially with ever-rising concerns for the environment betterment. To
make electric vehicles cheaper and affordable to everyone. We need to cut off the cost of
production, so reducing the rejection rate is one of the ways to reduce the cost, which can
save up to 10% of the total production cost.

Quality checks play an important role in delivering quality products. By implementing the
systematic quality flow, we can reduce the defects in the initial stage itself, thus saving further
resources. In this report, we will discuss the best practice that can be used to increase the
quality efficiency and identify the defects rates at the earliest.

4.2. Integrating the assembly line and quality assessment process:

Integrating the Quality assessment process with the assembly line has several benefits like a
reduction in the overall rejection rate, and it also helps to improve the quality of the product
and reduce the resources. The flow of the process will be designed in such a way to reduce
the bottlenecks, and software simulation will be conducted before the implementation stage.
By creating the virtual simulation, we are mimicking the real environment and finding the
optimal way in this way, and we are saving time and resources.

Identifying the Key Performance Indicators (KPI):

Before building the assembly, we need to identify the KPI to assess the quality and
performance of the product. It also narrows down the parameters to be checked during the
quality test. Since battery production is a complex process with the different critical
processes, and its safety concern is the highest priority. We need to provide the best product
to the customer at an affordable rate. A lot of competitors are entering the market to utilize
the forecasted huge demand.

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Quality products at an affordable rate can be done by optimizing the value chain process from
the ram material ordering to product shipment. Quality assessment is also included in the
value chain, so by optimizing the assembly line and quality assessment process, we can
improve the production volume and thus cater to the needs of the market place demands.

To identify the vital process, the data has to be collected from the various departments of the
manufacturing plant to get the perspective of the different departments and not to miss out
on any vital information. After the records have been gathered, the data has to clean to make
it ready for future analysis. From the cleaned data, descriptive analysis is conducted to know
the important parameters then these parameters are matched with the specifications of the
product and quality assessment requirements. After analyzing the descriptive analysis with
product specifications and quality assessment requirements, critical parameters are drawn
from the analysis. Then these parameters are given weightage depends upon their functions
and importance. The domain process experts give the weightage for each parameter, and
they also give the target values and tolerance limits, which can be used to optimize the
process. With these parameters and their respective weightage, the modeling outline is
drafted with real-time constraints. The model is then optimized for further process and then
evaluated. The outcome is then fed to the process chain and optimized.

Fig 4.2.1. Framework for Identifying, modeling, and optimizing the process chain:

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Designing a Quality assessment oriented assembly line:

To avoid defective high-value products from further processing, capable quality assurance
measurements have to be incorporated into the assembly processes. Collaborations between
the product development, assembly systems, and quality assurance, those three aspects have
to be considered at the same time in the initial planning phase.

As we have found the critical parameters earlier, we need to design an assembly line with
quality assurance. The design should be seamless and should be effective. The relevant quality
characteristics of the batteries to be produced and the different characteristics of quality-
critical processes are identified and transferred to detailed descriptions of the respective
measurement tasks. A catalog of relevant measurement equipment is set up considering both
the requirements of the planning configurator and each measurement task. The qualified
measurement systems are connected to the configurator via quality data information
modules.

Fig 4.2.2. Factors to consider for integrating the quality with assembly line:

Risk analysis of the gathered characteristics is conducted by a team of product and process
experts. With the help of the FMEA(Failure Mode and Effects Analysis ), possible causes or
consequences of failures and failures themselves are collected for each process step and
identified in the generic assembly process. The result of the FMEA(Failure Mode and Effects

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Analysis) is the risk priority number for each failure. In conclusion, quality critical process
steps and product characteristics can be identified. The aggregation of those quality
parameters that need checking provides a basis for a later selection and derivation of
measurement equipment.

Once the process and equipment have been finalized, the accuracy of the equipment is
checked by comparing the results from the equipment and laboratory test. The results have
been analyzed at a different position at different times to check the precision of the
equipment before implementing it in a real assembly line.

Fig 4.2.3. Comparing the results of the equipment and laboratory:

Product, Process, and Resources(PPR) framework:

The product, process, and resources framework will connect the product characteristics with
process and resources. Since the critical parameters are already decided, and process flows
are decided. This framework is then used to optimize the process, product, and resources,
which will help to streamline the resources and process to get the efficient product out of the
process.

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vueOne is an engineering toolset that supports the lifecycle of a production system. The
Automation Systems Group developed it at the University of Warwick. During the process
planning phase, system behavior is modeled through the combination of kinematics and state
transition diagrams (STDs). A specific type of software component within the tools created
for this work is the "Product Component," which contains the product geometry and the key
product feature information described. Once this link exists, it is maintained as each
respective component has a permanent ID through its lifecycle.

Fig 4.2.4. Product, Process, and Resources(PPR) framework:

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5. Conclusion:
The battery production is a complex process, and at the same time safety of the battery is the
most important factor. Quality control is vital to maintain the safety and standard of the
product. The demand for the battery is huge in the upcoming years, with technological
improvements and ecological concerns. More and more players started to research this area
to make it the safest and cheapest. One way is to reduce the wastage of the resources by
keeping the quality checks at certain intervals, which will also help the industry to identify its
operational efficiency at each stage and optimize according to the needs. The other way is to
design the flow process in an optimal way where it can reduce the cycle time and increase
production. So, in-line quality assurance in an assembly line with an optimal flow process can
both increase the efficiency and reduce the product cost. By systematically implementing this,
the manufacture can reduce the total production cost up to 8% - 10% and can reduce the
total defect rates from 15% to less than 9%.

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6. Learnings:
In this live project, I got several insights, both academic and personal as well. My learnings are
as follows,

Academic:

• Working of the manufacturing plant and its operations

• Importance of safety in manufacturing plant
• How important quality control to maintain the industry standards
• How rejection rates of the product affect the cost hugely
• The various battery manufacturing process
• How crucial to optimize the assembly line in any manufacturing plant
• Different operational streamlining to increase the operational efficiency
• Different quality control best practices in the industry

Personal:

• Organizational culture of different sectors both in government and private

• Difference between fixed mindset and growth mindset
• How behavioral aspects can increase in the productivity
• Different personality development best practices to improve self-confidence and self-
awareness
• How to overcome the stressful situation with creative thinking
• Importance of healthy habits in the work environment in the context of both current
and normal situation
• Time management in both professional and personal life
• How different domain knowledge can improve productivity in life

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REFERENCES:

• https://www.researchgate.net/publication/330902286_LITHIUM-
ION_BATTERY_CELL_PRODUCTION_PROCESS
• https://www.researchgate.net/publication/318352831_An_Application_of_Physical_Flexibili
ty_and_Software_Reconfigurability_for_the_Automation_of_Battery_Module_Assembly
• https://www.researchgate.net/publication/341059960_Multi-
Criteria_Optimization_in_the_Production_of_Lithium-Ion_Batteries/related
• https://www.researchgate.net/publication/275541772_Quality-
oriented_Production_Planning_of_Battery_Assembly_Systems_for_Electric_Mobility
• https://www.researchgate.net/publication/312084661_Quality_Management_for_Battery_
Production_A_Quality_Gate_Concept
• https://www.mordorintelligence.com/industry-reports/global-battery-market-industry
• https://en.wikipedia.org/wiki/Electric_battery

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