Digitization Platform – Simulation for battery manufacturing

Project duration:
01.10.2019 – 30.09.2022


  • TU Braunschweig, Institute of Machine Tools and Production Technology (IWF)
  • TU Braunschweig, Institute of Energy and Process Systems Engineering(InEs)
  • TU Braunschweig, Institute for Particle Technology (iPAT)
  • KIT, Institute for Production Engineering (wbk)
  • KIT, Institute of Mechanical Process Engineering and Mechanics (MVM)
  • KIT, Thin Film Technology (TFT)
  • TU Munich, Institute of Machine Tools and Industrial Management (iwb)
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TU Braunschweig
TU München

The manufacturing process of lithium-ion batteries consists of individual, coupled process steps. The coupling of these steps leads to complex interactions between the different levels of the considered parameters, i.e., relationship of process-structure-property parameters . The process parameters of the individual manufacturing steps influence the resulting structures within the battery. These structures significantly influence the electrochemical properties of the battery. Additionally, uncertainties arise in each manufacturing step, which propagate along the process chain and influence the electrochemical properties. This has an influence on the quality and costs of the battery cell.
Within the framework of the previous project “Sim2Pro”, the investigation of electrode manufacturing with the aid of three coupled process models for coating, drying and calendering was examined exemplarily. Thus, the influence of uncertainties of relevant process parameters in the manufacturing process on the structural parameters could be investigated and the propagation and effect through the different process steps could be analyzed. The determined distributed structural parameters were forwarded to the battery model and the distribution of the electrochemical properties was determined. It is shown that uncertainties or tolerance limits in different process steps have a varying effect on the dispersion of the properties.
Within the scope of the digitization platform, the Sim2Pro platform for simulation in battery cell production is to be extended. The focus will be on integrating new and more detailed process models for process engineering and manufacturing processes and improving the coupling between process chain simulation and battery cell simulation. The closer communication of the model parts enables the use of mathematical methods for robust optimization and sensitivity analysis. This enables a knowledge-based optimization of tolerances in the overall manufacturing process. In addition, an interface to the ProZell cost and life cycle assessment model is to be developed in the digitization platform in order to be able to answer economic and ecological questions.