Researchers at the Fraunhofer Institute for Industrial Mathematics ITWM are advancing battery performance through innovative simulations. By focusing on battery behavior during charging and discharging, optimizing production processes, and understanding battery aging, the team is enhancing the development of battery cells for electric vehicles. Their latest findings will be showcased at the Battery Show Europe 2025, scheduled for June 3 to 5.
A key component of battery cells is the electrodes, whose microscopic structure plays a crucial role in overall battery performance. Utilizing the BEST simulation software, Fraunhofer ITWM conducts detailed three-dimensional simulations of electrode microstructures. Dr. Jochen Zausch, team leader of Electrochemistry and Batteries, explained, “We can use these insights to predict how the cell will behave during charging and discharging and then make targeted optimizations to improve the performance and efficiency of the battery.”
In addition to performance optimization, the research team is addressing battery aging. Battery cells experience degradation during both active use and storage, influenced by factors such as mechanical stress and chemical side reactions. These processes can reduce capacity and increase internal resistance, thus impairing performance.
Dr. Falco Schneider, an expert in battery cell aging, stated, “We are working on gaining a better understanding of the cells and are researching how these special ageing processes can be slowed down in order to save resources and energy in battery production in the long term.” The latest version of the BEST software incorporates several aging models and analysis methods to support this research.
Fraunhofer ITWM is also involved in the state-supported project “Digitalization of Battery Cell Production to Create a Battery Twin for the Entire Product Life Cycle” (DiBaZ). This initiative focuses on simulating and optimizing key production steps, including electrode calendering, electrolyte wetting, cell formation, and foam encapsulation.
Dr. Konrad Steiner, project coordinator, highlighted, “Through the work in this project, we can offer our industrial partners methods and models that not only simulate processes from battery production, but also enable non-destructive quality control and include energy management with predictive control.”
The Fraunhofer ITWM has also further developed its terahertz measurement technology and offers new possibilities for inspecting the electrode coating for battery cells. Inspection systems based on terahertz radiation are non-contact and non-destructive optical methods. Most importantly, they are also completely harmless to health. “The results of tests on terahertz measurement technology are promising and show the great potential of this technology for the production of battery cells,” says Dr. Joachim Jonuscheit, deputy Head of the Department, Material Characterization and Testing, at the Fraunhofer ITWM.
At the upcoming Battery Show Europe 2025, Fraunhofer ITWM will demonstrate their inline layer thickness measurement of battery foil coatings and present the latest developments in their BEST simulation tool, along with advancements in physical cell and production process simulations.
Source: Auto Tech News
