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Battery industry under pressure

Virtual twins pave the way for more sustainable electromobility

Data helps in battery production - the more complex, the better. | Photo: Dassault Systèmes
Data helps in battery production - the more complex, the better. | Photo: Dassault Systèmes
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The EU Parliament in Strasbourg wants to seal the end for combustion engines and only allow emission-free new cars from 2035. This aims to accelerate developments in the electric mobility market and achieve the climate goals of the European Green Deal. This increases the pressure not only on OEMs but also on battery manufacturers. To keep pace in this crucial key industry, they must drive forward new technologies, secure material supply, and create the necessary production capacities. At the same time, individual mobility should remain affordable, and the environment cleaner.

Batteries are extremely complex: Therefore, leverage digitalization

European vehicle and battery manufacturers need to score points, if only to reduce dependence on Asian suppliers. According to a recent study by Transport & Environment (T&E), Europe could emerge from the shadow of Chinese manufacturers of lithium-ion batteries by 2027. In recent years, many billions have flowed into the research and scalable production of battery cells. As early as 2022, more than half of all lithium-ion batteries on the European market were manufactured in the EU, and by the end of the decade, Europe could become the second-largest manufacturer of battery cells in the world.

That's the theory - but what does reality look like? The fact is, the production of battery cells is extremely complex and not yet a fully automated process. Many manual interventions are still required, which can lead to quality problems and high rejection rates. At the same time, manufacturers are supposed to reduce costs, respond agilely to market dynamics, and shorten the time to mass production. Despite all these challenges, electromobility presents a significant opportunity for the German industry to establish itself as a player in the global market.

A crucial key to the transition to electromobility is digitalization. Building and scaling production sites can only succeed if manufacturers take a holistic view of their value chain and holistically map the numerous individual steps in the product lifecycle of a battery cell, from basic research through production and logistics planning to recycling.

Managing the value chain

The lifecycle of a battery begins with the extraction of raw materials. However, global crises, critical procurement, and increasing demand are depleting reserves. Capital and investment willingness for new mining projects are lacking. Opening a new mine alone can take between five and ten years. Furthermore, the introduction of the European battery pass is imminent. It aims to provide the necessary transparency to comply with content and technical standards and support ethical mining. The regulations of the "Battery Passport" project, initiated by industry and research partners, foresee the traceability of all data across all value creation stages. Consumers will quickly understand which batteries are installed, how they were manufactured, and how sustainable they are.

Domino effect: A damaged cell can affect others

The production of battery materials and components as well as the manufacturing of battery cells must meet high-quality standards. If a cell is poorly produced and not sorted out as usual, a domino effect could occur. A faulty cell generates a higher internal resistance during current flow, damaging other cells. This effect multiplies until the battery is no longer usable. Generally, the usable energy and performance of batteries decrease over time. OEMs typically guarantee a mileage of about 150,000 kilometers. Therefore, a sustainable battery lifecycle also includes second-life batteries and innovative recycling methods. For example, they can later be used in solar installations, which demand significantly less performance.

Integrating know-how and process management

The investments and risks in battery cell production are high. Therefore, manufacturers must apply new methods, processes, and technologies initially in pilot projects. The goal is to achieve a continuous core model that allows the testing of improved materials and processes. Only in the next step can they scale up their production and reach manufacturing capacities that guarantee economical production. This CapEx approach is suitable both within a gigafactory and in the construction and operation of multiple gigafactories.

Since many disciplines are involved in battery production, manufacturers should also promote networking and knowledge transfer across various fields: Engineering is responsible for developing suitable battery cells. Safety, power-to-weight ratio, service life, cost, and recyclability – all parameters can be defined and tested at this stage. Integrated modeling and simulation help make quicker, more informed decisions regarding regulations and allow adjustments parallel to modeling. Manufacturing planners develop production processes, and layout planners are responsible for building the gigafactories. Finally, logistics planners ensure an uninterrupted supply of production materials. All stages of the value chain interlock and should work in an orchestrated manner.

Optimize Real Processes with Virtual Twins

The virtual twin can act as a mediator here. With this digital representation of a real object or process, all information can be bundled in a 3D model, creating digital continuity and transparency throughout the entire value chain. The benefits are manifold, as different virtual twins can be built and interconnected depending on the application: Simulations, for example, provide more precise insights into the behavior of materials and the multi-physical properties of cells during the development process of a battery cell. At the same time, time and costs can be saved as fewer or no physical prototypes need to be created. Similarly, data such as drying times and temperatures, as well as properties of battery cells during the production process, can be recorded and transferred to the virtual twin. Everything from manufacturing processes to assembly lines, buildings, and supply chains can be simulated and optimized to ensure error-free development and production, plan the time horizon of delivery and sales forecasts, and conserve resources.

Data in the Cloud Can Provide Many Insights

Data collection via the cloud during the use of the battery and potentially up to the failure of the cell can provide important clues regarding wear progress. What cannot be traced back is simulated based on the measurement data. The totality of data from the merged virtual twins allows manufacturers to recognize various correlations in the life of a battery and thus optimize its development and production or further improve its quality.

It is correspondingly important that all stakeholders can access and work together on a common "Single Source of Truth" – a common data base – in real-time. Platforms like Dassault Systèmes' 3DExperience platform form the foundation as a central storage location. On them, all data and information from the battery creation process and battery usage are processed and managed bidirectionally.

What Does This Mean?

With the 3DExperience platform and the industry and brand applications from Dassault Systèmes, battery cell manufacturers can successfully realize their new production sites – scalable from the pilot project to the gigafactory. Virtual twins allow them to make the right decisions early on with the help of simulations, save resources, time, and costs, and optimally set up production.

This article was written by Ludwig Hunseder, CATIA Value Engagement Manager at Dassault Systèmes

 

Translated automatically from German.
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