Optimising Battery Cell Design and Production Process through Prototype Cell Finishing and Testing

Abstract

Due to the rapid development of battery cell design, an effective approach to validating cell prototypes is required that considers processes in near-series production. A systematic approach using large-format prototype cells under near-series conditions has not yet been introduced due to the novelty of this interdisciplinary research area and the requirement of high-safety standard. In this paper, we present an approach for cell prototype validation using large-format prismatic cells, considering the current market trend, to conduct data-based cell characterisation and evaluation. The main purpose of the cell prototype validation is to derive directions for future optimisation regarding both cell design and manufacturing. For this reason, the experimental protocol and experimental set-ups are described from cell inspection through cell finishing to performance testing. During cell finishing and testing, electrical and thermal data are collected to monitor battery cell behaviour and safety. By data analysis, battery cell prototypes can be characterised regarding capacity and internal resistance and assessed in different operating conditions through pulse charging and temperature variation. The results are described based on data analysis and provide insights into potential optimisation for next prototypes and manufacturing process design. For root cause analysis, laboratory analysis procedures are discussed to identify detected anomalies during thermal testing. This approach to prototype validation provides a foundation for driving optimisation in cell design and manufacturing. It has the potential to be extended to larger sample sizes, different cell types and new process technologies.

Authors 9

1. Deng Sicong Aachen Chair of Production Engineering of E-Mobility Components (PEM)

   RWTH Aachen University

   Affiliation as printed

   RWTH Aachen University,Chair of Production Engineering of E-Mobility Components,Aachen,Germany

2. Lukas Miederer Aachen Chair of Production Engineering of E-Mobility Components (PEM)

   RWTH Aachen University

   Affiliation as printed

   RWTH Aachen University,Chair of Production Engineering of E-Mobility Components,Aachen,Germany

3. Fabian Hoheisel Aachen Chair of Production Engineering of E-Mobility Components (PEM)

   RWTH Aachen University

   Affiliation as printed

   RWTH Aachen University,Chair of Production Engineering of E-Mobility Components,Aachen,Germany

4. Jonas Gorsch Aachen Chair of Production Engineering of E-Mobility Components (PEM)

   RWTH Aachen University

   Affiliation as printed

   RWTH Aachen University,Chair of Production Engineering of E-Mobility Components,Aachen,Germany

5. Raphael Friedrich Aachen Chair of Production Engineering of E-Mobility Components (PEM)

   RWTH Aachen University

   Affiliation as printed

   RWTH Aachen University,Chair of Production Engineering of E-Mobility Components,Aachen,Germany

6. Sebastian Wolf Aachen Chair of Production Engineering of E-Mobility Components (PEM)

   RWTH Aachen University

   Affiliation as printed

   RWTH Aachen University,Chair of Production Engineering of E-Mobility Components,Aachen,Germany

7. Henrik Born Aachen Chair of Production Engineering of E-Mobility Components (PEM)

   RWTH Aachen University

   Affiliation as printed

   RWTH Aachen University,Chair of Production Engineering of E-Mobility Components,Aachen,Germany

8. Heiner Hans Heimes Aachen Chair of Production Engineering of E-Mobility Components (PEM)

   RWTH Aachen University

   Affiliation as printed

   RWTH Aachen University,Chair of Production Engineering of E-Mobility Components,Aachen,Germany

9. Achim Kampker Aachen Chair of Production Engineering of E-Mobility Components (PEM)

   RWTH Aachen University

   Affiliation as printed

   RWTH Aachen University,Chair of Production Engineering of E-Mobility Components,Aachen,Germany