Multi-scale simulation of laser welding for optimal battery pack manufacturing

Purpose and goal:

The use and manufacturing of batteries in the automotive industry started about a decade ago with the purpose and objective of producing long-range highway compatible electric vehicles. With the current increasing demand in industry to produce more efficient energy sources, the manufacturing of electrical components must be of high quality and ensure the intended performance.

The project will thus study and optimize joining processes for different stages of battery production, from battery cells to battery packs. Expected results and effects:

New technologies will be developed during the project with the main goal of optimizing the joining process and ensuring the quality of laser-welded battery packs. The techniques, ranging from thermal processes during laser welding to structural and electromagnetic behaviors of the assembled battery packs, are expected to provide added value to reduce development lead times and optimize material use.

With the aid of digital twins, different scenarios can be tested and optimized in a virtual environment before production. Approach and implementation:

The project consists of 7 work packages and runs over 36 months. The total transnational project budget is SEK 12,384,530 and the grant amount granted for the Swedish project participation is SEK 4,393,786,