Digital Twin Technology Drives Major Improvements in Battery Efficiency and Cost

The demand for more efficient and cost-effective batteries continues to grow with a global push towards renewable energy and electric vehicles. The increased demand is testing the limits of current manufacturing capabilities, which requires the expansion of capacity, improved efficiency and cost-effectiveness.

How can new technologies help meet these challenges? Recent analysis examined the potential of digital twins in the battery manufacturing setting. According to such analysis, integrating digital twins can reduce costs by up to 80% and significantly improve development efficiency.

This article will detail the quantitative and qualitative benefits of adopting digital twin technology throughout the different steps of battery production.

Understanding the digital twin technology

A digital twin, as the term suggests, is a virtual replica of a physical object, system or process. Digital twins integrate various technologies such as artificial intelligence, big data, IoT, APIs, virtual and augmented reality technologies, blockchain, collaborative platforms and open standards, to create a digital dynamic model of a real-world system.

The underlying technologies continuously feed the digital twin with real-world data. The process enables real-time insights regarding the present and future performance and problems of this object, system or process.

In the context of batteries, a battery digital twin (BDT) is a highly detailed virtual model of a real-world battery system. It can be used to enhance decision-making and optimize battery performance in the physical world.

A BDT leverages:

●     Real-time sensor data embedded in the physical battery which continuously collects and transmits performance data.

●     Computational models simulating the physical and mechanical behaviors of the battery. The models predict potential variations in behaviors under different circumstances based on the laws of physics.

The benefit of utilizing a BDT lies in the ability to predict potential issues, optimize performance and plan maintenance more effectively. Thereby, improving the efficiency of the real-world counterpart.

Current battery manufacturing challenges

The "traditional approach" to manufacturing batteries is far from efficient and often contributes to inefficient and long production times. On average, a battery prototype requires a development cycle of 36–60 months and a cost of over 1 million USD. Using a digital twin, production costs can be cut by up to 80% by eliminating errors and cutting the development time to 9–15 months.

Figure 1: A comparison of development time and cost between traditional and digital twin battery prototyping. Credit: PreScouter.

Increasing physical space and labor does not necessarily translate to the capacity of a manufacturer due to other inherent problems that come with battery production. These include material shortage, increasing battery yields, decreasing impurities, improving quality control issues, addressing safety concerns and scaling issues.

Although digital twins cannot solve all  these problems, the technology can make for smarter use of resources, more efficient testing, improved battery performance and lifespan, safer work environments and lower maintenance costs. Inadvertently, such benefits translate into more sustainable energy storage solutions.

Benefits of BDTs on battery manufacturing and usage processes

The BDT product enables structured analysis of various cell designs intermediate and end products, supporting data-driven decisions in new battery cell development.

Figure 2: The key benefits of battery digital twins. Credit: PreScouter. 

Operational benefits

The BDT helps identify and address potential issues pre-production, leading to improved cell performance, extended battery lifespan and reduced defects. In addition, the technology offers insights into cell degradation over time, which enables the design and production adjustments for better performance and durability. Inherently, the process aids in the development of safety measures identifying any potential manufacturing and operational risks.

Furthermore, BDTs facilitate the assessment and validation of new battery cell technologies by simulating new materials and designs. The sophisticated simulation capabilities help companies to rapidly evaluate and refine innovative solutions without the need for extensive physical prototyping. As a result, product development cycles are dramatically shortened and accelerate market introduction.

SES, a technology company specializing in advanced energy storage solutions, focusing on developing high-energy-density lithium-metal batteries, provides a valuable real-world example of the impact digital twins can have on battery manufacturers. The SES Avatar, a digital twin of physical Li-Metal cells, leverages manufacturing and real-world battery data to enable predictive performance and longevity analysis.

SES has seen major achievements thanks to the adoption of BDTs including enhanced battery energy density, faster-charging properties, advanced monitoring, development of cost-effective products and rapid commercialization of these products.

Financial benefits

Tangible financial benefits underscore the transformative potential of BDTs in the battery industry, making it a crucial tool. Below are some key financial benefits of utilizing BDTs:

●     Identify and address potential pre-production issues, resulting in a 46% improvement in cell performance, a 60% longer battery lifespan and a 30% reduction in lifetime costs.

●     Offers insights into cell degradation, allowing for design and production adjustments that extend the battery life cycle by 30%.

●     Engineering expenses are reduced by 20%.

●     Facilitates the assessment and confirmation of new battery cell technologies through virtual simulations, significantly speeding up product development. The time to market is reduced from 36–60 months to just 9–15 months, cutting development costs by approximately 17.6% per project and lowering emissions by 50%.

Making battery management systems better

Battery management systems (BMS) play a critical role in bridging the physical battery and its digital representation. BMS allow for monitoring and safeguarding battery reliability, safety and efficiency.

Traditionally, BMS have focused on basic monitoring functions such as tracking current, voltage and temperature, in addition to ensuring safety by intervening when readings deviate from safe levels. However, current BMS technologies still face limitations due to unreliable battery algorithms, limited computing capabilities and restricted data storage capacity.

Integrating BDT technology can revolutionize BMS capabilities, addressing its current limitations. Some improvements in BMS thanks to BDTs include:

●     Improvement in the accuracy of predicting state of charge and state of health, which are critical for battery life and safety.

●     A more adaptive and precise control of battery temperature, maintaining optimal performance and preventing overheating.

●     The ability to identify and address potential issues, thus improving overall battery safety and reliability.

●     Ability to forecast maintenance needs, reducing downtime and extending battery life.

●     A real-time optimization of battery performance based on current conditions and usage patterns.

Example use case: Li-ion batteries and the high scrap rate during mass production

The production of Li-ion battery cells still faces challenges related to scrap rates and quality control, partly due to the complex relationships between production processes and final product quality. Ongoing research and development efforts are focused on better understanding and optimizing these relationships to improve efficiency and reduce waste in battery manufacturing.

BDTs can help to provide better information by capturing and analyzing extensive data produced during battery production. The analyses can help to visualize and identify which quality variances preclude products from being functionally identical. 

Data structuring and process optimization

Data structuring is crucial for process optimization. The relevance of the problem is not only the need to compare data obtained through the cell manufacturing process but this will be affected by the size of the operation. For instance, Tesla's GigaFactory Nevada has a production capacity of 37 GWh per year. A 21,700 battery cell has an energy content of ~18 Wh.

The company produced ~1.7 billion cells in a single year. BDTs can help structure, partition and analyze data that can help to identify patterns, make decisions, and improve production processes.

Predictive maintenance and process control

BDTs can use detailed information on all intermediate products. Data on raw materials and individual components make it possible to understand new and existing correlations through process simulation and data analytics. For example, quality properties measured after the electrode slurry mixing process can be utilized to adjust parameters in the subsequent coating process.

The versatility of the BDT ensures its adaptability to different cell formats, chemistries, production processes and quality inspections, ultimately enhancing the entire battery cell production chain.

Cost and efficiency gains

Relating to electric vehicles, BDTs can lead to a 20% reduction in cell costs per kilowatt-hour, lower capital expenses and utility costs and improve yield rate. Moreover, production-related costs (excluding materials) could be slashed by 20% to 35% across major battery cell production steps.

Cost reduction can be achieved through the significant reduction of errors and the time required to bring a product to market, from an average of 36–60 months down to just 9–15 months, also reducing development costs by approximately 17.6% per project.

Future outlook

The implementation of BDT technology represents a transformative shift in the battery industry. By significantly reducing production costs, enhancing performance, and facilitating innovation, BDTs offer a strategic advantage to manufacturers. As the technology continues to mature and more use cases emerge, the widespread adoption of BDTs is expected to revolutionize battery development, paving the way for a more efficient, sustainable and competitive industry.

The value added by digital twin technology in the battery industry will grow substantially in the coming years. As more companies recognize the benefits of BDTs, investments in this technology are likely to increase, further driving its development and adoption. The future of batteries, powered by digital twins, promises not only improved performance and reduced costs but also a more sustainable and efficient approach to energy storage.