Development of a Digital Twin for Improved Ramp-Up Processes in the Context of Li-Ion-Battery-Cell-Stack-Formation

Husseini, Kamal; Schmidgruber, Nils; Weinmann, Hannes W.; Maibaum, K.; Ruhland, Janna; Fleischer, Jürgen

doi:10.1016/j.procir.2022.02.150

Cited by 15 publications

(6 citation statements)

References 9 publications

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“…A digital twin of the machine has been introduced by Husseini et al [ 26 ] to simulate the behavior of the equipment before starting the actual operation. This allows for the early optimization of different machine parameters and thus an even faster change of the processed materials and the different electrode sizes.…”

Section: The Flexible Cell Stacking Processmentioning

confidence: 99%

“…The Gen. 1 machine ("Coil2Stack") in the context of battery cell manufacturing; Reproduced with permission. [26] Copyright 2022, Elsevier. Furthermore, to assure a quick ramp-up of cell variants in terms of format and material with a low scrap rate while meeting the quality requirements, the fitting process parameters have to be found quickly.…”

Section: Objective and Approach For Quality Planningmentioning

confidence: 99%

mentioning

confidence: 99%

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Quality Assurance for Flexible Stack Assembly of Lithium‐Ion Cells

et al. 2023

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The development and scale‐up of lithium‐ion battery (LIB) production for a sustainable energy supply is advancing very rapidly and in versatile directions. Manufacturing processes and production steps are constantly developed and optimized to improve production efficiency. To integrate new machinery into a production line while conforming to the DIN EN ISO 9001 standards of certification, it is necessary to define the procedures for assuring product quality. Herein, a quality assurance concept is designed for an innovative flexible stacking process currently under development. Critical sources of errors are identified by employing the failure process matrix approach. On this basis, it is described how these errors are either avoided by suitable design of the machine components and its control or by which inspection technology is integrated to detect defective intermediate products. In the resulting quality assurance concept, a digital twin of the stacking machine is employed to constantly surveil process and product properties and also to facilitate the change of the produced products on the machine. Evaluating the quality management already in the design phase of the machine saves resources and enables a deeper understanding of the stacking process.

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Section: The Flexible Cell Stacking Processmentioning

confidence: 99%

Section: Objective and Approach For Quality Planningmentioning

confidence: 99%

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Quality Assurance for Flexible Stack Assembly of Lithium‐Ion Cells

et al. 2023

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“…For the model-based optimization of the web tension control, the digital twin described in ref. [22] is used. It consists of a system simulation using the software Simcenter Amesim.…”

Section: Digital Model Of the Coil2stack Machinementioning

confidence: 99%

mentioning

confidence: 99%

Model‐Based Optimization of Web Tension Control for the Flexible Cell Stack Assembly of Lithium‐Ion Battery Cells

et al. 2022

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The transformation toward electromobility presents a significant challenge to the battery cell production processes. It is, therefore, necessary to establish efficient and robust operations and machines to meet the forecasted demand for manufactured cell capacity. Currently, the development and ramp‐up phases of production machines, especially for cell stack assembly, are characterized by high material scrap rates and large personnel expenses. Aspects such as the web tension of electrodes or separator materials during separation and stack assembly have a significant influence on the subsequent intermediate product properties, and therefore present a key challenge. Herein, the optimal methodology for the web tension control of electrode materials is determined via a model‐based approach by the means of a digital twin. The focus is hereby set on a production machine for the flexible cell stack assembly. Appropriate control methods are implemented and validated on the real system, thus reducing material scrap rates and overall costs. The control of the web tension by means of an unwinder and material storage was found to be optimal on the basis of the model and confirmed experimentally.

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Model‐Based Exploration of Web Guiding Behavior for a Novel Battery Cell Stacking Process

Husseini,

Gupta,

Schabel

et al. 2024

Energy Tech

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Innovative production processes are required to meet the rapidly growing demand for batteries and the associated material trends. In particular, the process step of stack assembly using new machine concepts promises a high potential for optimization. However, these concepts are untested in practice. The use of digital models makes it possible to develop corresponding optimization approaches. This article presents the development of a model for the web guiding systems of electrodes and its integration into an overall machine model for a novel machine concept. Finally, optimization approaches are identified by determining appropriate controller parameters for the web guiding systems.

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Development of a Digital Twin for Improved Ramp-Up Processes in the Context of Li-Ion-Battery-Cell-Stack-Formation

Cited by 15 publications

References 9 publications

Quality Assurance for Flexible Stack Assembly of Lithium‐Ion Cells

Quality Assurance for Flexible Stack Assembly of Lithium‐Ion Cells

Model‐Based Optimization of Web Tension Control for the Flexible Cell Stack Assembly of Lithium‐Ion Battery Cells

Model‐Based Exploration of Web Guiding Behavior for a Novel Battery Cell Stacking Process

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