Evaluation of Modelling and Simulation Strategies to Investigate the Mechanical Integrity of a Battery Cell Using Finite Element Methods

The mechanical integrity of a lithium ion battery cell can be evaluated using finite element (FE) simulation techniques. In this study, different FE modelling approaches including heterogeneous, homogeneous, hybrid and sandwich methods are presented and analysed. The basic capabilities of the FE-methods and their suitability to simulate a real mechanical safety test procedures on battery cells are investigated by performing a simulation of a spherical indentation test on a sample pouch cell. For each modelling approach, one battery cell model was created. In order to observe the system behaviour, relevant parametric studies involving coefficient of friction and failure strain of separator were performed. This studied showed that these parameters can influence the maximum force and the point of failure of the cell. Furthermore, the influence of an anisotropic separator on the results was also investigated. The advantages and disadvantages of each modelling approach are discussed and a simplified approach with a partial cell modelling is suggested to further reduce the simulation time and complexity

Methodology for Defining the Interaction between Product Characteristics and Specific Product Complexity—Evaluated on Electrodes for Lithium-Ion Batteries

This study is about a method for evaluating specific product complexity. In this context, an efficient and scalable method for the development of a specific complexity assessment of highly complex products is presented. Furthermore, existing evaluation methods are analysed according to effort and benefit, thus showing the research gap and the need for the method to be developed. The procedure for the development of an indicator for the specific evaluation of product complexity is presented in five steps and an exemplary complexity indicator for lithium ion battery cells is developed. This index is then applied, and the complexity of commercial battery cells from the application is evaluated. Based on these evaluations, final potentials of the method are shown and a recommendation for a reduction in product complexity is provided. The developed method for complexity assessment is scalable in its effort and offers implementation into existing complexity management. The method allows quick adaptation or extension and, thus, well-founded decision making. By standardizing the evaluation and taking objectively measurable complexity characteristic values as a basis, a holistic and objective evaluation tool is shown, which can thus become a decisive success factor for manufacturers of complex products.BMBF, 02PJ1100, Verbundprojekt: Synergetische Entwicklung mechatronischer Produkte in Wertschöpfungsnetzwerken (SynProd); Teilprojekt: Berücksichtigung produkt- und produktionsseitiger sowie betriebswirtschaftlicher RestriktionenDFG, 414044773, Open Access Publizieren 2021 - 2022 / Technische Universität Berli

Evaluation of Modelling and Simulation Strategies to Investigate the Mechanical Integrity of a Battery Cell Using Finite Element Methods

The mechanical integrity of a lithium ion battery cell can be evaluated using finite element (FE) simulation techniques. In this study, different FE modelling approaches including heterogeneous, homogeneous, hybrid and sandwich methods are presented and analysed. The basic capabilities of the FE-methods and their suitability to simulate a real mechanical safety test procedures on battery cells are investigated by performing a simulation of a spherical indentation test on a sample pouch cell. For each modelling approach, one battery cell model was created. In order to observe the system behaviour, relevant parametric studies involving coefficient of friction and failure strain of separator were performed. This studied showed that these parameters can influence the maximum force and the point of failure of the cell. Furthermore, the influence of an anisotropic separator on the results was also investigated. The advantages and disadvantages of each modelling approach are discussed and a simplified approach with a partial cell modelling is suggested to further reduce the simulation time and complexity.</jats:p

Methodology for Defining the Interaction between Product Characteristics and Specific Product Complexity—Evaluated on Electrodes for Lithium-Ion Batteries

This study is about a method for evaluating specific product complexity. In this context, an efficient and scalable method for the development of a specific complexity assessment of highly complex products is presented. Furthermore, existing evaluation methods are analysed according to effort and benefit, thus showing the research gap and the need for the method to be developed. The procedure for the development of an indicator for the specific evaluation of product complexity is presented in five steps and an exemplary complexity indicator for lithium ion battery cells is developed. This index is then applied, and the complexity of commercial battery cells from the application is evaluated. Based on these evaluations, final potentials of the method are shown and a recommendation for a reduction in product complexity is provided. The developed method for complexity assessment is scalable in its effort and offers implementation into existing complexity management. The method allows quick adaptation or extension and, thus, well-founded decision making. By standardizing the evaluation and taking objectively measurable complexity characteristic values as a basis, a holistic and objective evaluation tool is shown, which can thus become a decisive success factor for manufacturers of complex products.</jats:p