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Battery Production for Electric Vehicles
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Battery Production for Electric Vehicles

A special issue of World Electric Vehicle Journal (ISSN 2032-6653).

Deadline for manuscript submissions: closed (28 February 2023) | Viewed by 23247

Special Issue Editors

Dr. Heiner Hans Heimes

E-Mail Website
Guest Editor
Production Engineering of E-Mobility Components (PEM), RWTH Aachen University, 52072 Aachen, Germany
Interests: battery production; battery development; battery testing; production digitalization; electromobility; sustainability; future mobility
Prof. Dr. Achim Kampker

E-Mail Website
Guest Editor
Chair for Production Engineering of E-Mobility Components, RWTH Aachen University, 52064 Aachen, Germany
Interests: battery production; fuel cell; electric drive; sustainability; electromobility; future mobility

Special Issue Information

Dear Colleagues,

The transformation of mobility toward electrification is in full swing. The electrification of transport relies on battery technology.

This Special Issue will focus on battery production and its enablement. Process innovations that positively influence production will also be discussed here. This positive development can be expressed, for example, through lower costs, reduced scrap rates or the increased quality of the batteries. Moreover, the innovations should increase the sustainability of battery production. The Special Issue also focuses on the accompanying processes for production. In terms of the complete battery product life cycle, other components in the battery development and usage are also covered. Innovations in battery cell design—which, among other things, optimize performance in later operation or manufacturability—are integrated. Concepts for the end-of-life of batteries are essential for the sustainable use of electromobility. Accordingly, the recyclability of the systems plays a role in increasing resource efficiency.

Dr. Heiner Hans Heimes
Prof. Dr. Achim Kampker
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. World Electric Vehicle Journal is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 1400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • battery production
  • battery cells
  • battery development
  • battery end-of-life

Published Papers (6 papers)

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Research

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19 pages, 8204 KiB  
Article
Research on SOC Estimation Method for Lithium-Ion Batteries Based on Neural Network
by Chuanwei Zhang, Xusheng Xu, Yikun Li, Jing Huang, Chenxi Li and Weixin Sun
World Electr. Veh. J. 2023, 14(10), 275; https://doi.org/10.3390/wevj14100275 - 02 Oct 2023
Viewed by 1407
Abstract
With the increasingly serious problem of environmental pollution, new energy vehicles have become a hot spot in today’s research. The lithium-ion battery has become the mainstream power battery of new energy vehicles as it has the advantages of long service life, high-rated voltage, [...] Read more.
With the increasingly serious problem of environmental pollution, new energy vehicles have become a hot spot in today’s research. The lithium-ion battery has become the mainstream power battery of new energy vehicles as it has the advantages of long service life, high-rated voltage, low self-discharge rate, etc. The battery management system is the key part that ensures the efficient and safe operation of the vehicle as well as the long life of the power battery. The accurate estimation of the power battery state directly affects the whole vehicle’s performance. As a result, this paper established a lithium-ion battery charge state estimation model based on BP, PSO-BP and LSTM neural networks, which tried to combine the PSO algorithm with the LSTM algorithm. The particle swarm algorithm was utilized to obtain the optimal parameters of the model in the process of repetitive iteration so as to establish the PSO-LSTM prediction model. The superiority of the LSTM neural network model in SOC estimation was demonstrated by comparing the estimation accuracies of BP, PSO-BP and LSTM neural networks. The comparative analysis under constant flow conditions in the laboratory showed that the PSO-LSTM neural network predicts SOC more accurately than BP, PSO-BP and LSTM neural networks. The comparative analysis under DST and US06 operating conditions showed that the PSO-LSTM neural network has a greater prediction accuracy for SOC than the LSTM neural network. Full article
(This article belongs to the Special Issue Battery Production for Electric Vehicles)
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23 pages, 4146 KiB  
Article
Concept for Digital Product Twins in Battery Cell Production
by Achim Kampker, Heiner Hans Heimes, Benjamin Dorn, Henning Clever, Robert Ludwigs, Ruiyan Li and Marcel Drescher
World Electr. Veh. J. 2023, 14(4), 108; https://doi.org/10.3390/wevj14040108 - 13 Apr 2023
Cited by 2 | Viewed by 3165
Abstract
This paper presents an approach for the design and derivation for establishing a digital product twin for battery cells. A digital product twin is a virtual replica of a physical battery cell and can be used to predict and optimize quality properties and [...] Read more.
This paper presents an approach for the design and derivation for establishing a digital product twin for battery cells. A digital product twin is a virtual replica of a physical battery cell and can be used to predict and optimize quality properties and performance in real-time. The study focuses on pouch cell manufacturing and aims to map the large amount and variety of process information down to purchased parts and interim products. The approach for this study was to collect and analyze data from the physical production process and use this information to structure a digital battery product twin based on its product architecture. The main findings of this study indicate that a digital product twin can be effectively structured and implemented in a digital interface based on its product architecture in combination with data from the physical production process. The results of this study show the potential of digital product twins, in which statements about material, design, and behavior can be made using real information from production. Further research will focus on the practical application and implementation of digital product twins in a battery cell pilot production. Full article
(This article belongs to the Special Issue Battery Production for Electric Vehicles)
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15 pages, 1676 KiB  
Article
Framework and Classification of Battery System Architectures
by Achim Kampker, Heiner Hans Heimes, Christian Offermanns, Janis Vienenkötter and Tobias Robben
World Electr. Veh. J. 2023, 14(4), 88; https://doi.org/10.3390/wevj14040088 - 30 Mar 2023
Cited by 2 | Viewed by 4648
Abstract
In this paper, battery system architectures are methodologically derived in order to find the key type differences. In a first step, the system levels are identified and distinguished. In order to be able to completely cover the solution space of battery system architectures, [...] Read more.
In this paper, battery system architectures are methodologically derived in order to find the key type differences. In a first step, the system levels are identified and distinguished. In order to be able to completely cover the solution space of battery system architectures, a distinction is also made between mono- and multifunctional materials. Based on the system levels, a framework for possible architectures is derived. Four system architecture generations with a total of eight different types are identified and analyzed in the dimensions “Nomenclature”, “Approach”, “Omitted Components” and “Industry Examples”. In this way, upcoming system architectures, such as cell-to-pack and cell-to-chassis, can be clearly differentiated. Finally, fundamental product characteristics for the four system generations are derived and compared. Full article
(This article belongs to the Special Issue Battery Production for Electric Vehicles)
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Review

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26 pages, 4329 KiB  
Review
Optimizing the Cell Finishing Process: An Overview of Steps, Technologies, and Trends
by Achim Kampker, Heiner Heimes, Christian Offermanns, Sarah Wennemar, Tobias Robben and Nikolaus Lackner
World Electr. Veh. J. 2023, 14(4), 96; https://doi.org/10.3390/wevj14040096 - 04 Apr 2023
Cited by 3 | Viewed by 5934
Abstract
The cell finishing process is the final stage in the production of a battery cell. Almost one third of the production costs of a battery cell are related to this part of the production. It includes a series of steps and technologies aimed [...] Read more.
The cell finishing process is the final stage in the production of a battery cell. Almost one third of the production costs of a battery cell are related to this part of the production. It includes a series of steps and technologies aimed at optimizing the battery cell’s performance, quality, and safety. The process is divided into three categories: pre-treatment, formation procedure, and quality testing. The order of the processes and the time required for each step can vary depending on the manufacturer and the cell format. Recent trends in optimizing the cell finishing process include the integration of a second filling process for larger prismatic cells and the optimization of the formation protocol or Electrochemical Impedance Spectroscopy (EIS) as possible methods for quality inspection. Efforts are also being made to reduce the pre-treatment time and improve the degassing process to ensure cell performance, quality, and safety. In this paper, all process steps of the cell finishing process are presented, and their function and technological implementation in the industry are explained. Future innovations are analyzed in terms of time to market and the potential to optimize the process in terms of quality, time, and cost. Full article
(This article belongs to the Special Issue Battery Production for Electric Vehicles)
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14 pages, 1329 KiB  
Review
Identification of Challenges for Second-Life Battery Systems—A Literature Review
by Achim Kampker, Heiner Hans Heimes, Christian Offermanns, Janis Vienenkötter, Merlin Frank and Daniel Holz
World Electr. Veh. J. 2023, 14(4), 80; https://doi.org/10.3390/wevj14040080 - 24 Mar 2023
Cited by 2 | Viewed by 3695
Abstract
Lithium-ion batteries (LIBs) have been proven to be increasingly popular and are the solution of choice for many companies and business models around the world. One major question for battery owners is how to deal with returning batteries if they still contain sufficient [...] Read more.
Lithium-ion batteries (LIBs) have been proven to be increasingly popular and are the solution of choice for many companies and business models around the world. One major question for battery owners is how to deal with returning batteries if they still contain sufficient capacity for operation. In this case, those energy storages can still be used in different, less-required second-life applications, such as stationary battery storage systems, contributing to increased product sustainability and economic benefits at the same time. However, the second-life business model is still at an early stage of development due to the young EV market in combination with long vehicle lifetimes. As a consequence, there are several barriers in various thematic fields, complicating the rededication process for LIBs. This review paper focuses on a summary of barriers to second-life adoption published with scientific reference. Furthermore, barriers are clustered thematically to provide a transparent landscape picture and valuable insights into the rededication process of LIBs. Full article
(This article belongs to the Special Issue Battery Production for Electric Vehicles)
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Other

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25 pages, 4806 KiB  
Perspective
Cost-Benefit Analysis of Downstream Applications for Retired Electric Vehicle Batteries
by Achim Kampker, Heiner H. Heimes, Christian Offermanns, Moritz H. Frieges, Maximilian Graaf, Natalia Soldan Cattani and Benedikt Späth
World Electr. Veh. J. 2023, 14(4), 110; https://doi.org/10.3390/wevj14040110 - 14 Apr 2023
Cited by 3 | Viewed by 2853
Abstract
Mass transport conversion to an electrified powertrain requires suitable strategies for processing electric vehicle (EV) batteries after their intended first service life. Due to aging mechanisms, EV batteries lose capacity over their period of use and become unsuitable for their initial application at [...] Read more.
Mass transport conversion to an electrified powertrain requires suitable strategies for processing electric vehicle (EV) batteries after their intended first service life. Due to aging mechanisms, EV batteries lose capacity over their period of use and become unsuitable for their initial application at some point. However, to expand their lifetime and to meet the sustainability demand for EVs, the usage of these batteries in so-called Re-X applications is under intense discussion. Until now, downstream processing has been subject to high uncertainty regarding the expected advances. While many issues on the technical and ecological side have been at least partially resolved, the economics are still under assessment. For this reason, this paper intends to give a well-based outlook on the costs and benefits of three chosen scenarios: reuse, repurpose, and recycle. It is expected that under the given national policies and global market conditions, growing quantities of retired EV batteries will return from the transportation markets. Consequently, the market potential for retired batteries in downstream applications will significantly increase, as well as calls for stable solutions. Full article
(This article belongs to the Special Issue Battery Production for Electric Vehicles)
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