Simulation Based Approach for High-Throughput Stacking Processes in Battery Production

Abstract

What are the benefits of simulation-driven design and optimization of stacking processes in battery cell production? This question is addressed within the scope of the paper. This work proposes a method to reduce the effort for model-based design and optimization. Based on three case studies which originate from the development of high-speed stacking processes, this paper illustrates how the relevant loads on the intermediate products are determined with the help of the method. Subsequently, it is shown how the specific material models for battery electrodes and separators are identified, created and validated, as well as how process models are created and process limits are identified and optimized. It was possible to prove how process simulations can be used to minimize the effort required to validate developments and to efficiently determine optimized process parameters for a format and material change in a model-based manner. Consequently, more and more model-based processes should be taken into account during development and start-up in the future.

Enhanced Deposition Accuracy for Battery Electrodes in a Novel High-Speed Stacking Process

“…The gentle handling especially refers to the reduction of particle contamination and mechanical stresses. Mechanical stresses can induce damages such as cracks or delamination of the coating, especially when handling thick electrodes [4,5]. Cross-contamination of coating particles is a source for short circuits.…”

Model‐Based Design and Experimental Evaluation of a High‐Throughput Electrode Feeding and Stacking Process

“…This chapter presents two case studies for the design of a novel assembly process with continuous material flow based on rotational handling units. [ 7,13 ] The process consists of five phases and comprises two types of rotating handling units – the separation unit and the paddle wheel – as shown in Figure 2 . To feed the paddle wheel with both anode and cathode, the entire process requires two separation units.…”

“…Its main components are the conveyor belt, the paddles, the ejection pin, the positioning elements, and the stacking table. As shown in Figure 2 and described by, [ 7,13 ] the stacking process consists of three phases: 1) the insertion and deceleration phase; 2) the transportation phase; and 3) the ejection and positioning phase. During the three phases, the main components of the paddle wheel perform different functions.…”

“…High edge contact forces can lead to bending of the electrode and may influence the capacity of the cell. [ 7 ] Therefore, the reduction of the edge contact forces is the focus of the process design. The following section conducts an analysis on the components related to edge contact forces to identify key design variables.…”

“…The experimental evaluation of a high number of parameters is taxing on time and resources. [ 7 ] Therefore, simulations usually represent a time, material, and cost‐effective approach to evaluate different parameters. However, to assure a sufficient accuracy of the simulations, a profound understanding for the process and process–product–interactions – often based on historical data – is required.…”