Hexagon announced the launch of a new battery cell design solution leveraging both electrochemical simulation technology from the Fraunhofer Mathematical Research Institute ITWM and multiphysics materials simulation and metrology software from Hexagon.
Developing a new battery cell is both a complex and time-consuming process. Research and development involves laborious procedures, including the establishment of a design of experiment (DoE) and first-principles-based simulations to explore new electrochemical configurations. These theories are then subjected to physical tests in the laboratory. Each step in the manufacturing of these cells can influence not only the rejection rate, but also their final performance.
Hexagon’s new electrochemical battery design solution integrates Fraunhofer ITWM’s Battery and Electrochemistry Simulation Tool (Best) solver into Hexagon’s Digital Materials suite to enable multiphysics exploration of cell designs taking into account the effects of battery processes. manufacturing.
This “virtual laboratory” has advantages in terms of costs and productivity. Its user interface allows modeling the microstructure of the electrodes through to the complete cell assembly (electrolyte, separator, active material, binder, current collector) from an integrated library of battery materials.
Customers can also explore the impact that changes in material properties and battery microstructure have, among other things, on improving performance outcomes (energy efficiency, lifespan, optimal charging protocols) through selection of appropriate materials and configurations, including particle size distribution and carbon binder distribution.
Examining the impact of manufacturing processes on cell microstructure, including the ability to reverse engineer the internal structure of manufactured cells from a CT scan and Hexagon’s powerful VGStudio Max 3D metrology software as well that the study of battery aging and the safety implications of cell design to establish an optimal charging protocol for the battery management system are also concerned.
« Cell design and development presents major challenges due to the complexity of choosing between materials, electrochemical design, mechanical design and manufacturing processes. Much of this complex process has relied on trial-and-error cycles to date, but through our partnership with Fraunhofer ITWM, we are confident we can help R&D teams improve the performance of battery cell designs and develop them more quickly thanks to rapid return of prototypes », explains Guillaume Boisot, senior director of the materials & platforms department at Hexagon.
Subham Sett, vice president of the Multiphysics unit at Hexagon, adds: “ Battery performance and quality are competitive differentiators, particularly in the automotive market. We have invested in our thermal management and runaway simulations. With this new addition, we are confident that we can help manufacturers gain a more holistic view of these multiphysics interactions as they redefine the design process. »
“We benefited from excellent technical collaboration to integrate our electrochemical battery solver – Best – with Hexagon’s innovative materials modeling software. Now, we look forward to helping advance new battery innovations faster through this comprehensive simulation process,” note Jochen Zausch from the Fraunhofer ITWM Institute.
The new electrochemical battery design solution integrates Fraunhofer ITWM’s Best solver with Hexagon’s materials behavior modeling software, Digimat, part of the HxGN Digital Materials suite. Through its user interface, users can simulate the electrochemistry of a cell’s microstructure, electrolyte, separator, active material, binder, and current collector for common lithium-ion cell configurations, as well as zinc and sodium battery chemicals, using advanced electrochemical modeling techniques from Fraunhofer ITWM.
Digimat includes a library of common material properties that can be expanded within the software or using Hexagon’s MaterialCenter and Materials Connect materials data management software. Microstructures can be imported from CT scans using VGStudio Max or created directly in Digimat.
Additionally, battery design teams can apply their microstructure model developed in Digimat to further study mechanical properties. Material behavior at the macroscopic scale can be assessed using a representative volume element (RVE), which extends the model’s capability for structural analyzes of the cell, by integrating a simplified Digimat material model to the appropriate mechanical analysis software. Mechanical engineers can thus evaluate the mechanical performance of the “jelly roll” to optimize the mechanical design and safety of the battery based on the precise properties of the material.
