Getting More Out of the Battery with Simulations
Modern simulation tools and innovative measurement techniques to drive forward the further development of battery cells for electric cars
Researchers at the Fraunhofer Institute for Industrial Mathematics ITWM are using innovative technologies to focus on battery behavior during charging and discharging, the optimization of battery production and the aging of batteries. They use modern simulation tools and innovative measurement techniques to drive forward the further development of battery cells for electric cars.
The electrodes are a central component of battery cells. The microscopic structure of the electrodes has a decisive influence on the behavior of the entire battery cell. The Fraunhofer ITWM's BEST simulation software makes it possible to simulate the three-dimensional microstructure of electrodes in detail. Through these simulations, our researchers gain important insights into the behaviour of the battery cell: »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« explains Dr. Jochen Zausch, team leader of »Electrochemistry and Batteries«.
Predicting Battery Aging by Simulation
Battery cells age both during active use and during storage. There are many factors that influence the ageing behavior. For example, mechanical stress during operation can cause parts of the cell to become inactive such that they no longer contribute to charge exchange. In addition, chemical side reactions take place, which result in a loss of capacity and increased internal resistance, which impedes performance. »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 « explains Dr. Falco Schneider, expert in battery cell ageing. Several ageing models and analysis methods are integrated into the latest version of the BEST software.
Simulation-Based Optimization of Battery Production
The researchers at Fraunhofer ITWM are also focusing on battery production, which is being driven forward in the state government-funded project »Digitalization of Battery Cell Production to Create a Battery Twin for the Entire Product Life Cycle«, or DiBaZ for short. A key aspect is the simulation and optimization of the central steps in the production of batteries, such as calendering the electrodes, electrolyte wetting and battery cell formation or foam encapsulation of cells within modules for insulation, using proven tools such as FeelMath, FLUID and FOAM.
DiBaZ brings together various areas of expertise at the Fraunhofer ITWM to develop a digital twin for all process steps in battery production. »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« explains Dr. Konrad Steiner, coordinator of the project.
Quality Assurance in Battery Production
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.
Presentation at the Battery Show Europe 2025
At the Battery Show Europe 2025 from June 3 to 5, the experts will be represented with an exhibit on inline layer thickness measurement of battery foil coatings. The researchers will also be presenting the latest developments of our simulation tool BEST as well as possibilities for physical cell simulation and the simulation of battery production processes.
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Topic World Battery Technology
The topic world Battery Technology combines relevant knowledge in a unique way. Here you will find everything about suppliers and their products, webinars, white papers, catalogs and brochures.