Digital Methods for the Production and Application of Battery Cells

In cross-departmental teams at the Fraunhofer ITWM, we develop a wide range of digital methods that address the field of application of electrochemical storage systems – mainly lithium-ion batteries – particularly with regard to electromobility. Among other things, digital twins of the battery and the production processes are being created. This will enable manufacturing companies to improve the quality and efficiency of their next-generation battery production in the future.

In many places in Europe, including Rhineland-Palatinate, the construction of factories for battery cell production is currently being driven forward at full speed – particularly in order to satisfy the enormous increase in demand for battery cells for electromobility and to be less dependent on other markets internationally. Digitalization is providing valuable support in the construction and operation of such plants.

Digital Solutions for Sustainable and Efficient Battery Cell Production

The »DiBaZ« project funded by the state of Rhineland-Palatinate, among others, has pooled the expertise of various of our departments in order to support these processes at different levels by developing and applying digital methods. In particular, this involves:

• the further development of physical simulation methods for describing individual battery production steps
• the development of inline-capable test methods for quality control – in particular measurements of electrode thickness and homogeneity
• predictive control of the entire production chain – mainly with regard to energy consumption
• the physical simulation of cell behavior to support cell design and prediction of battery properties
• the simulation of battery behavior and load in the application scenario (driving operation), so that aging and temperature aspects in particular can be coupled with a digital overall vehicle model.

Cooperation and Practical Support in the Fraunhofer-Gesellschaft

We are closely networked within the Fraunhofer-Gesellschaft via the Fraunhofer Battery Alliance and were supported in the »DiBaZ« project in particular by the Fraunhofer »Research Fab Battery Cell FFB« with practical know-how on the production processes and the provision of measurement data.