Periodic Reporting for period 1 - BATSS (SAFE EFFICIENT BATTERY SYSTEM BASED ON ADVANCED CELL TECHNOLOGY)
Berichtszeitraum: 2024-01-01 bis 2025-06-30
Most of the current research efforts are focused on improving Li-ion batteries performance and lifetime. Nevertheless, battery safety is of great importance to increase the confidence of the end users as well as to facilitate the arrival of battery technologies to new markets other than electric vehicles (EV), such as off-road mobile devices or waterborne transport. Thus, there is a need to include safety in the battery system (BS) design stage, so it becomes a relevant criterion to ensure and improve the safety levels in all stages of the value chain, from manufacturing to use and End of Life (EoL) steps.
The aim of BATSS is to achieve a TRL5 BS design that can cover different transport and mobile applications with an enhanced performance through the whole life cycle, ruled by Safe-by-Design (SbD) principles and based on an advanced cell technology. More specifically the pursued specific objectives (SO) of BATSS are:
• SO1. Design a BS that can be used in different type of electric vehicles and mobile applications.
• SO2. Guided by safe-by-design principles, develop an innovative cell-to-pack BS concept in order to reach a higher electrical, thermal and mechanical performance, based on an advanced cell technology.
• SO3. Simulate in detail the behaviour of the BS including extreme conditions that can lead to safety issues, with special highlight on fire related ones and define countermeasures or avoidance measures.
• SO4. Improve (dis)assemblability of the BS by optimizing manufacturing key processes and by developing assessment tools for the recycling and second life potential uses.
• SO5. Asses the proposed BS and potential end uses through life cycle assessment (LCA) and life cycle cost (LCC) methodologies.
• SO6. Communicate, disseminate and analyse the achieved results exploitation paths.
BATSS has established an impact pathway to achieve the expected outcomes specified in the HORIZON-CL5-2022-D2-01-05 topic, and the wider impacts, in the long term, specified in the destination “Cross-sectoral solutions for the climate transition” in the Cluster 5 work programme:
• Outcome 1 and 2. Next generation battery systems with increased performance and safety for transport and mobile applications.
• Outcome 3. Reduced manufacturing, refurbishment, dismantling and recycling (EoL) costs of battery systems.
• Impact 1. Increased global competitiveness of the European battery ecosystem through generated knowledge and leading-edge technologies in battery materials, cell design, manufacturing and recycling.
• Impact 2. Accelerated growth of innovative, competitive and sustainable battery manufacturing industry in Europe.
• Impact 3. Accelerated roll out of electrified mobility through increased attractiveness for citizens and businesses, offering lower price, better performance and safety, reliable operation of e-vehicle.
The aim of BATSS is to achieve a TRL5 BS design that can cover different transport and mobile applications with an enhanced performance through the whole life cycle, ruled by Safe-by-Design (SbD) principles and based on an advanced cell technology. More specifically the pursued specific objectives (SO) of BATSS are:
• SO1. Design a BS that can be used in different type of electric vehicles and mobile applications.
• SO2. Guided by safe-by-design principles, develop an innovative cell-to-pack BS concept in order to reach a higher electrical, thermal and mechanical performance, based on an advanced cell technology.
• SO3. Simulate in detail the behaviour of the BS including extreme conditions that can lead to safety issues, with special highlight on fire related ones and define countermeasures or avoidance measures.
• SO4. Improve (dis)assemblability of the BS by optimizing manufacturing key processes and by developing assessment tools for the recycling and second life potential uses.
• SO5. Asses the proposed BS and potential end uses through life cycle assessment (LCA) and life cycle cost (LCC) methodologies.
• SO6. Communicate, disseminate and analyse the achieved results exploitation paths.
BATSS has established an impact pathway to achieve the expected outcomes specified in the HORIZON-CL5-2022-D2-01-05 topic, and the wider impacts, in the long term, specified in the destination “Cross-sectoral solutions for the climate transition” in the Cluster 5 work programme:
• Outcome 1 and 2. Next generation battery systems with increased performance and safety for transport and mobile applications.
• Outcome 3. Reduced manufacturing, refurbishment, dismantling and recycling (EoL) costs of battery systems.
• Impact 1. Increased global competitiveness of the European battery ecosystem through generated knowledge and leading-edge technologies in battery materials, cell design, manufacturing and recycling.
• Impact 2. Accelerated growth of innovative, competitive and sustainable battery manufacturing industry in Europe.
• Impact 3. Accelerated roll out of electrified mobility through increased attractiveness for citizens and businesses, offering lower price, better performance and safety, reliable operation of e-vehicle.
During the first reporting period (RP1), two main activities were accomplished in WP2, the definition of requirements, specifications and challenges for the battery system and its use cases (marine, off-road and stationary use-case), on one hand and the improvement of the cell welding process, on the other hand. WP3 was focused on cells electrical and thermal modelling, considering usual operation and TRA (Thermal Runaway). The single cell analysis was upscaled to system level and the optimal integration of the cooling system was studied. In WP4 the main goal was to define an E/E architecture suitable for the specified use cases. More precisely this activity was focused on the development of the master-slave structure of the BMS, SiC-based power switch, cloud communication and DC/DC converter. Prototypes were manufactured for all these components and preliminary validations executed. In WP5 the full-scale version of each use case was developed at CAD level and a downscaled module, representative of the final use cases was designed, manufactured and tested. The design followed SbD principles and a mixture of cell-to-pack and modularity concepts. The design procedure included a specific chapter on fire-related countermeasures. In close relation with WP2 standards to be considered for the battery system design and simulation were agreed. WP6 had a lower activity during RP1 since it is mainly dedicated to the analysis of the final battery system, which was a work in progress during this time. It included some transversal activities such as the set up of the FMEA procedure to support the design and the definition of the necessary data for the second life and LCX analysis, that will be completed in the second period of the project.
The main results achieved in RP1 can be summarised as:
• BS initial specifications, requirements and challenges were defined.
• The cell electro-thermal preliminary model was finished.
• The overall activity related to the BS design, modelling, simulation, manufacturing, recycling, second life and standardization has been reviewed and validated.
• BS initial specifications, requirements and challenges were defined.
• The cell electro-thermal preliminary model was finished.
• The overall activity related to the BS design, modelling, simulation, manufacturing, recycling, second life and standardization has been reviewed and validated.