Automated Guided Vehicles (AGVs) play a critical role in modern battery manufacturing plants, where they transport sensitive materials such as electrodes, electrolytes, and assembled battery cells. However, the operational environment in battery production presents unique hazards, including flammable solvents, reactive materials, and the risk of thermal runaway. Ensuring AGV safety in these settings requires specialized protocols, explosion-proof designs, and compliance with international standards such as IEC 62998 for safety-related control systems.
One of the primary concerns in battery plants is the presence of dry rooms, where humidity is tightly controlled to prevent moisture contamination during electrode manufacturing. These areas often contain flammable solvents used in slurry mixing, creating an explosive atmosphere. AGVs operating in dry rooms must adhere to explosion-proof (Ex) standards, typically meeting ATEX or IECEx certifications. Key design features include sealed electrical enclosures, intrinsically safe circuits, and non-sparking materials to prevent ignition sources. Brushless motors and pneumatic tires are often used to minimize friction and static electricity buildup.
Navigation in hazard zones requires additional safeguards. Traditional laser-guided or vision-based AGV systems may not suffice in areas with high concentrations of volatile organic compounds (VOCs) or lithium-ion cell assembly lines. In such cases, magnetic tape or inductive guidance systems are preferred due to their immunity to environmental interference. AGVs must also be programmed to avoid restricted zones where electrolyte filling or formation processes occur, as accidental collisions could lead to spills or short circuits.
Electrolyte spillage poses a significant risk, particularly in areas where AGVs transport liquid electrolytes or freshly filled battery cells. AGVs designed for these tasks incorporate spill containment trays and corrosion-resistant materials such as stainless steel or specialized coatings. Sensors for leak detection can trigger immediate shutdown procedures if a spill is detected, while automated cleanup protocols may involve diverting the AGV to a designated isolation area.
Thermal runaway scenarios demand proactive mitigation strategies. AGVs operating near formation or aging chambers must be equipped with thermal sensors to detect abnormal heat generation. If a cell begins overheating, the AGV must have predefined evacuation routes to remove adjacent cells from the hazard zone without human intervention. Emergency stop systems compliant with IEC 62998 ensure that AGVs can be halted remotely or autonomously if thermal events are detected. These systems integrate with the plant-wide safety network to initiate fire suppression protocols and alert personnel.
Battery manufacturing AGVs must also address electrostatic discharge (ESD) risks, particularly when handling electrode materials or cell components. Conductive flooring, grounding straps, and ionizing bars are commonly integrated into AGV designs to dissipate static charges. Additionally, AGVs transporting electrodes or separators may operate in cleanroom environments, requiring HEPA-filtered ventilation systems to prevent particulate contamination.
Communication and fail-safe mechanisms are critical for AGV safety. Redundant wireless networks, such as dual-band Wi-Fi or private LTE, ensure continuous connectivity for real-time monitoring and emergency overrides. In the event of signal loss, AGVs must default to a safe state—either coming to an immediate stop or following a preprogrammed low-risk path. Battery-powered AGVs themselves must use lithium-ion packs with integrated battery management systems (BMS) that monitor cell voltages, temperatures, and isolation faults.
Training and procedural controls complement technical safeguards. Operators and maintenance personnel must be trained in AGV-specific emergency responses, including manual override procedures and spill containment measures. Regular safety audits should verify that AGV routes do not intersect with high-risk processes unless absolutely necessary, and that collision avoidance systems are calibrated to the plant’s hazard zones.
Compliance with IEC 62998 ensures that AGV safety systems meet rigorous performance criteria for risk reduction. This includes validated safety functions such as speed monitoring, obstacle detection, and emergency braking. Safety-rated encoders and lidar systems provide redundant position verification, while software-based checks enforce speed limits in hazardous areas.
In summary, AGVs in battery plants require tailored safety measures to address explosion risks, electrolyte spills, and thermal hazards. Explosion-proof designs, spill-resistant construction, and IEC 62998-compliant control systems form the foundation of safe operation. By integrating advanced sensors, fail-safe navigation, and robust communication networks, AGVs can enhance efficiency without compromising safety in high-risk battery manufacturing environments. Continuous evaluation of emerging risks and evolving standards will further refine AGV safety protocols as battery technologies advance.