Fraunhofer Research Institution for Battery Cell Production FFB Process Simulation Enables Battery Industry to Make Millions in Savings
Fraunhofer FFB, the Chair of Production Engineering of E-Mobility Components (PEM) of RWTH Aachen University and Capgemini has published the results of a recent study on the potential of process simulation in battery cell production. The background to this is the high reject rates and quality losses during the battery industry’s ramp-up process. According to a global Capgemini study, around 68 percent of companies in the automotive sector report corresponding difficulties in complying with standards on a large scale.
“Europe’s battery industry is facing the transition from its ramp-up phase to mass production,” says FFB Managing Director Professor Achim Kampker. “In particular, manufacturers are faced with the challenge of guaranteeing product quality and reducing scrap rates.” The early production steps in particular – such as mixing, coating, drying, and calendering – are susceptible to quality deviations. In order to get these under control, a thorough understanding of the process dynamics and the influence of certain machines on the quality of the electrodes produced is necessary. A white paper by the Fraunhofer FFB together with the RWTH Chair, the PEM Motion spin-off and the technology consultancy “Capgemini” shows how this can be achieved.
On 30 pages, the English-language study presents the use of process simulations as an innovative approach to support cell manufacturers. “The profitability of battery cell production is increasing at the same rate as the understanding of one’s own production processes,” says PEM Management Member Professor Heiner Heimes. “Whoever has the most precise simulation models is also likely to lead the market.” The authors claim that the targeted use of this digital assistance leads to improved quality control, a reduction in development time of up to 50 percent, a reduction in production waste of around three percent, and therefore a significant increase in overall performance. According to the study, cell manufacturers with an annual production volume of 50 gigawatt-hours can achieve savings of up to 138 million euros in this way.
The white paper “Quality Excellence in Battery Cell Production: The Power of Process Simulation” is available as a free download:
Download Whitepaper
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