CATL’s Debrecen gigafactory produces high-performance lithium-ion batteries for electric vehicles (EVs), with an annual capacity of 100 GWh—enough to power 1.2 million EVs. The factory’s battery production process relies on 400+ PLC-controlled equipment units, requiring millisecond-level data synchronization between equipment and the central DCS to maintain precise control over coating thickness, electrolyte injection volume, and cell sealing pressure. The legacy communication modules presented critical operational challenges:
- Unstable Data Transmission Causes Defects: The legacy modules had a data transmission latency of 15 ms and a packet loss rate of 2.3%, leading to delayed equipment response and process deviations. This resulted in a 4.7% battery cell defect rate—costing €4.2 million annually in wasted materials and rework.
- Poor Compatibility with High-Precision Equipment: The old modules couldn’t support the high-speed communication requirements of new coating machines and laser cutting equipment, limiting production line speed to 60% of maximum capacity. This created bottlenecks and reduced annual output by 10 GWh.
- Vulnerability to Humid Environment: The gigafactory’s electrode coating and electrolyte injection areas have high humidity (60-80%), causing corrosion and short circuits in legacy modules. This led to 12-15 communication module failures monthly, each resulting in 2-3 hours of production line downtime.
- Inadequate Data Traceability: The legacy systems lacked secure, real-time data logging capabilities required for EV battery production compliance (e.g., EU Battery Regulation). Manual data recording was required for 30% of process parameters, leading to a 4.1% data entry error rate and regulatory compliance risks.
“Battery cell quality directly impacts EV safety and performance—even minor process deviations can render a battery cell unusable,” said Wang Tao, CATL Debrecen Gigafactory Operations Director. “Our legacy communication modules couldn’t deliver the stable, high-speed data transmission needed for precise battery production. We needed a rugged, high-performance communication solution that could ensure millisecond-level synchronization, withstand humid environments, and support full data traceability.”
ABB NDBU-95C 64008366: High-Precision Communication for Battery Production
After evaluating solutions from Siemens and Omron, CATL selected the ABB NDBU-95C 64008366 communication module for its ultra-low latency, high compatibility, humidity-resistant design, and secure data logging capabilities. Key features addressing CATL’s pain points include:
- Ultra-Low Latency Data Transmission: The ABB NDBU-95C 64008366 offers a data transmission latency of <1 ms and a packet loss rate of <0.01%, enabling millisecond-level synchronization between production equipment and the central DCS. This ensures precise control over critical battery production processes, eliminating process deviations.
- High Compatibility with Precision Equipment: Supports high-speed industrial Ethernet protocols (PROFINET IRT, EtherNet/IP CIP Sync) that meet the communication requirements of advanced coating machines, calenders, and laser cutting equipment. This allows production lines to operate at 100% capacity, increasing annual output by 10 GWh.
- Humidity & Corrosion Resistance: Features an IP65-rated enclosure with a special anti-corrosion coating, protecting against high humidity (up to 95% non-condensing) and chemical vapors from electrolyte materials. Its sealed connectors and moisture-resistant components eliminate humidity-related failures, increasing mean time between failures (MTBF) to 180,000 hours.
- Secure & Compliant Data Logging: Integrates with CATL’s quality management system (QMS) via OPC UA Secure Connection, providing real-time, tamper-proof logging of 100% of process parameters. This meets EU Battery Regulation requirements and reduces data entry errors by 100%.
- Redundant Communication Paths: Equipped with dual Ethernet ports and support for ring topology redundancy, the module ensures uninterrupted data transmission even if one communication path fails. This enhances system reliability and reduces production line downtime.
Results: Higher Quality, Faster Production, Lower Costs
Six months after deploying the ABB NDBU-95C 64008366 communication module, CATL’s Debrecen gigafactory achieved significant operational improvements:
| Metric |
Before ABB NDBU-95C 64008366 |
After ABB NDBU-95C 64008366 |
Improvement |
| Battery Cell Defect Rate |
4.7% |
0.52% |
89% Reduction |
| Annual Production Output |
90 GWh |
100 GWh |
11% Increase |
| Monthly Communication Module Failures |
12-15 |
0-1 |
97% Reduction |
| Annual Rework & Waste Costs |
€4.2 Million |
€462,000 |
89% Reduction |
| Data Entry Error Rate |
4.1% |
0% |
100% Elimination |
“The ABB NDBU-95C 64008366 module has been a critical upgrade for our gigafactory operations,” Wang said. “The ultra-low latency communication has drastically reduced battery cell defects, and the module’s reliability has allowed us to reach full production capacity—enabling us to meet the growing demand for EV batteries in Europe. The secure data logging also ensures we remain fully compliant with strict EU regulations.”
David Lin, ABB’s Asia Pacific New Energy Automation Manager, commented: “EV battery production requires communication modules that deliver absolute precision, reliability, and compliance. The ABB NDBU-95C 64008366 is designed to meet the unique challenges of high-speed, high-precision battery manufacturing, helping manufacturers improve quality, increase output, and reduce costs.”
CATL plans to deploy the ABB NDBU-95C 64008366 communication module across 15 additional gigafactories in Europe, North America, and Asia by 2038, targeting a 90% group-wide reduction in battery cell defects and a 10% increase in production efficiency.
Stuttgart, Germany – September 2031 – Robert Bosch GmbH, a global leader in industrial technology and automotive components, has achieved 99.9% real-time data synchronization and a 40% reduction in production line downtime at its Stuttgart smart factory after deploying the ABB NDBU-95C 64008366 communication module. The upgrade, completed in Q2 2031, replaced the factory’s outdated industrial communication modules, which struggled with slow data transmission and frequent communication interruptions—critical bottlenecks for the factory’s IoT-enabled smart production systems.
