Why the EV Revolution Requires Battery Evolution

The big story today is the drive to improve while maintaining and enhancing the safety of batteries. Design and optimization of cell chemistry will pave the way to achieving this goal, and all the time we are seeing new breakthroughs – like lithium-sulfur batteries or solid-state electrolyte batteries – which promise to be safer while also having higher energy density.

– Lalitha Subramanian, Senior Director and Fellow, BIOVIA
 

Simulation’s ability to model complex behaviors from the atomic scale up is incredible in helping design safer and more high-performant batteries.

• Molecular dynamics simulations help researchers identify materials that will power the next generation of powerful, resilient, and cost-effective batteries. 
• Finite Element Modeling techniques allow developers to analyze stress, strain, and heat distribution within battery cells, and design robust, thermally-efficient cells.
• Microstructural simulations allow designers to optimize electrolyte, aging, safety, and performance of batteries. 
• System-level simulations model entire battery packs, from interactions between single cells and battery management systems (BMS) or degradation mechanisms.

And, by reducing prototyping and improving right-first-time, it also means that we can deliver next-gen batteries whilst cutting cost- and time-to-market.

– Rudy Pastuzak, Battery Industry Solution Experience Director, ENOVIA

A key challenge facing battery supply chains will be meeting skyrocketing demand for key materials like lithium, cobalt, nickel, manganese, and copper; particularly when new mines are not opening fast enough – and a new mine can take more than a decade to become operational. Long-term partnerships will be essential in ensuring adequate supply. That can mean opening new mines. But others are starting to seriously explore recycling, not just a sustainability play, but as a source of battery materials.

– Nicolas Vallin, Battery Expert, Transportation & Mobility Industry

The future battery cell factory will be very large, occupying several thousand square meters. Human participation will be greatly reduced; machinery will be extensively automated, and autonomous guided vehicles (AGVs) will be common – allowing for round-the-clock operation. Digital solutions, like virtual twins, will facilitate operator decision-making, and power new capabilities like predictive maintenance, remote monitoring, smart parameter setting, or smart inline control.

– Simon Mellier, Industry Process Consultant, DELMIA

One of the key benefits of virtual twins is battery developed is enabling effective collaboration between otherwise siloed parts of the value chain.

• Developers and materials providers can collaborate on a single model of the battery factory. 
• Machine makers and the battery cell designers can share technical models and reduce back-and-forth between different design teams. 
• Process engineers and product engineers can evaluate production feasibility, ensure right-first-time operations, and reduce time-to-volume. 
• Operations managers can establish real time visibility by combing model and shop-floor data, and identify and remediate operational issues.

– Simon Mellier, Industry Process Consultant, DELMIA

Simulation allows for the virtual testing of various manufacturing parameters, such as electrode coating, electrolyte mixing, and cell assembly, and can identify optimal conditions for consistent quality and performance. Simulation can also be used to train workers, enhance skill levels, accelerating onboarding and improve overall productivity. All this can lead to improved quality, higher yields, enhanced efficiency, and reduced waste and cost, giving battery makers the competitive edge.

– Rudy Pastuzak, Battery Industry Solution Experience Director, ENOVIA

Making truly sustainable batteries is a complex and multifaceted task, but those looking to build a sustainable and circular battery business must:

• Select materials with minimal environmental and political impacts.
• Optimize energy efficiency to limit resource consumption and waste.
• Extend battery lifetimes, reducing disposal and replacement.
• Design for easy disassembly and regeneration of the component materials.
• Encourage the use of recycled batteries in less demanding and critical applications.
• Ensure compliance with regulations like the Battery Passport.

– Lalitha Subramanian, Senior Director and Fellow, BIOVIA

All these challenges require clear visibility of product, factory, and supply chain. Virtual Twin Experiences provide battery makers with the visibility to build successful circular business practices right across the battery life cycle.

– Nicolas Vallin, Battery Expert, Transportation & Mobility Industry