Development of a Parallel Product-Production Co-design for an Agile Battery Cell Production System

Ruhland, Janna; Storz, Tobias; Kößler, Florian; Ebel, A.; Sawodny, Julia; Hillenbrand, J.; Gönnheimer, Philipp; Overbeck, Leonard; Lanza, Gisela; Hagen, Markus; Tübke, Jens; Gandert, Julia C.; Paarmann, Sabine; Wetzel, Thomas; Mohacsi, Jonas; Altvater, Andreas; Spiegel, Sandro; Klemens, Julian; Scharfer, Philip; Schabel, Wilhelm; Nowoseltschenko, Konstantin; Müller-Welt, Philip; Bause, Katharina; Albers, Albert; Schall, Daniel; Grün, Thorsten; Hiller, Marc; Schmidt, A.; Weber, André; Biasi, Lea de; Ehrenberg, Helmut; Fleischer, Jürgen

doi:10.1007/978-3-030-90700-6_10

Cited by 8 publications

(5 citation statements)

References 3 publications

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“…The design tool is not limited regarding cell size and edge lengths. The limitations considered in this work originate completely from the production plant regarded [11]. However, an expansion of the design tool for different production systems or changes with further development of the current system is conceivable.…”

Section: Discussionmentioning

confidence: 99%

“…Moreover, the approach of product-production codesign is pursued [11], especially focusing on agile production. On the one hand, this leads to some limitations in the design space, but on the other hand, this approach allows for an optimal utilization of the agile production line and enables the validation of the design tool with the cells produced.…”

Section: Methodology Of the Design Processmentioning

confidence: 99%

“…The battery production in European research institutions and industry is already, although slowly, experiencing a transition from the exclusively mass production of standard cells towards the additional operation of more agile production plants, which enable the profitable manufacturing of lower batch sizes and a more flexible choice of materials and cell shapes [11][12][13][14][15][16].…”

Section: Introductionmentioning

confidence: 99%

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Methodology for the Holistic Design of Format-Flexible Lithium-Ion Battery Systems

Gandert,

Mühlpfort,

Müller-Welt

et al. 2024

International Journal of Energy Research

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Most battery cells are developed according to a standard design and optimized regarding their electrical properties. However, firstly, there is a demand for an individual cell design adapted to the application. Secondly, additional properties, for example, thermal and mechanical, are decisive for the cell behavior and should be considered in the overall design. Therefore, the present work introduces a model-based development tool for the holistic design of format-flexible battery cells, which are optimized for their future application, allowing for different cell geometries within one battery system. The different approaches and simulation models for the single design steps are presented, and the prediction of the electrochemical, electrical, and thermal behaviors of the cell and whole battery system is described. A key aspect here is the appropriate interconnection of the single models in a way that helps to narrow down the multitude of interacting parameters in a systematic manner and, thus, makes a holistic design possible. In a last step, the functionality of the tool is shown in a case study by means of an e-bike battery pack.

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Section: Discussionmentioning

confidence: 99%

Section: Methodology Of the Design Processmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Methodology for the Holistic Design of Format-Flexible Lithium-Ion Battery Systems

Gandert,

Mühlpfort,

Müller-Welt

et al. 2024

International Journal of Energy Research

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“…For a more agile production line, this means that more measurement equipment is needed in the dryer (film thickness measurement, for example) to be able to adjust the drying profile to new materials. [63] The process must be able to adapt to the conditions of the materials. Here, one advantage of a longer dryer may be to have more control and flexibility where to change the drying rate exactly in the drying process.…”

Section: Microstructure Formationmentioning

confidence: 99%

Challenges and Opportunities for Large‐Scale Electrode Processing for Sodium‐Ion and Lithium‐Ion Battery

Klemens,

Wurba,

Burger

et al. 2023

Batteries & Supercaps

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Sodium‐ion batteries are an emerging technology that is still at an early stage of development. The electrode processing for anode and cathode is expected to be similar to lithium‐ion batteries (drop‐in technology), yet a detailed comparison is not published. There are ongoing questions about the influence of the active materials on processing parameters such as slurry viscosity, coating thicknesses, drying times, and behavior during fast drying. Herein, the expected drying time for the same areal capacity of anodes (graphite vs. hard carbon) and cathodes (lithium iron phosphate vs. Prussian blue analogs) are compared based on respective specific capacities reported in the literature. Estimates are made for the materials’ impact on production speed or dryer length. Within the experimental part, water‐based slurries of the same composition are mixed using different active materials according to identical procedure and the viscosity is compared. When drying at a constant drying rate (0.75 g m−2 s−1), lithium iron phosphate electrodes with different areal capacities (1–3 mAh cm−2) are shown to have the highest adhesion. For high drying rates (3 g m−2 s−1) at constant areal capacity, especially the investigated electrodes based on hard carbon show that no binder migration occurs.

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“…Due to their high energy density, lithium-ion batteries are currently used as accumulators in electric vehicles and hybrid electrical vehicles (including plug-in hybrid electric vehicles) [ 5 ]. Depending on the area of application, different battery cell variants are used that have been technically adapted to the respective application [ 6 ]. Existing variants of lithium-ion batteries differ in the housing type [ 7 ], the electrode geometries [ 8 ], and the chemical composition of the active layers [ 9 ].…”

Section: Introductionmentioning

confidence: 99%

Seam Properties of Overlap Welding Strategies from Copper to Aluminum Using Green Laser Radiation for Battery Tab Connections in Electric Vehicles

et al. 2023

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Laser beam welding of metals has progressed dramatically over the last years mainly arising from joining applications in the field of electromobility. Allowing the flexible, automated manufacturing of mechanically, electrically, and thermally stressed components, the process is more frequently applied for joining highly reflective materials, for example for battery tab and busbar connections. The local, non-contact energy input favors this welding technology; however, joining of copper and aluminum sheets still poses a challenge due to the physical properties of the joining partners and intermetallic phases from dissimilar metal interaction, which reduce seam performance. The use of green laser radiation compared to infrared laser radiation offers the advantage of a significantly increased absorptivity for copper materials. A changed incoupling behavior is observed, and a lower deep penetration threshold has been already proven for 515 nm wavelength. When copper and aluminum are welded with the former as top sheet, this welding mode is essential to overcome limited aspect ratios from heat conduction welding. However, the opportunities of applying these beam sources in combination with spatial power modulation to influence the interconnection area of copper-aluminum joints have not yet been studied. The aim of this work is therefore to investigate the seam properties and process stability of different overlap welding strategies using green laser radiation for dissimilar metal welding. A microstructural analysis of the different fusion zones and mechanical strength of the joints are presented. In addition, the experimental parameter sets were analyzed regarding their application in battery module busbars by examining the electrical resistance and temperature distribution after welding. A parameter window was identified for all investigated welding strategies, with the stitched seam achieving the most stable results.

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Development of a Parallel Product-Production Co-design for an Agile Battery Cell Production System

Cited by 8 publications

References 3 publications

Methodology for the Holistic Design of Format-Flexible Lithium-Ion Battery Systems

Methodology for the Holistic Design of Format-Flexible Lithium-Ion Battery Systems

Challenges and Opportunities for Large‐Scale Electrode Processing for Sodium‐Ion and Lithium‐Ion Battery

Seam Properties of Overlap Welding Strategies from Copper to Aluminum Using Green Laser Radiation for Battery Tab Connections in Electric Vehicles

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