Battery cell production is characterized by a complex process chain with diverse relationships between process and structure properties. The linking of individual steps leads to complex interactions between the different levels of the process and structure parameters. The process parameters of each manufacturing step have an influence on the resulting structures within the battery. These structures have a significant influence on the electrochemical properties of the battery. At the same time, production uncertainties arise in each manufacturing step, which propagate along the process chain and influence the electrochemical properties. Lastly, it has an impact on the quality and costs of the battery cell.
Based on the previous project Sim2Pro, which examined the electrode production using three coupled process models, the resulting platform for simulation in battery cell production will be expanded. The focus will be on integrating new and more detailed process models and improving the coupling between process chain simulation and battery cell simulation. The integration of further process models will also increase the scope of the structural parameters under consideration. In addition, the coupled production-product simulation will allow to examine the effects of process fluctuations within production on the properties of manufactured battery cells. This is of great importance for the industrial series production of battery cells, since the reduction of process fluctuations is normally associated with high costs.
The digitization platform addresses the high complexity of battery cell production. The goal is to provide a deeper understanding of process and structure relationships by linking process chain and battery cell simulation. A combination of the model parts enables the use of mathematical methods for robust optimization and sensitivity analysis. In detail, the IWF is responsible for integrating existent models and simulations in a digital platform and developing a process simulation to describe the process and structure relationships along the process chain. The results form the basis for process cost as well as process resource efficiency functions and enable a comprehensive ecological and economic evaluation.