Next generation technologies for battery systems in transport electrification based on novel design approach to increase performance and reduce carbon footprint

Project Information

NEXTBAT

Grant agreement ID: 101103983

DOI

10.3030/101103983

EC signature date 21 April 2023

Start date 1 June 2023

End date 30 November 2026

Funded under

• Climate, Energy and Mobility

Total cost

€ 4 966 937,50

EU contribution

€ 4 966 935,00

Coordinated by

TEKNOLOGIAN TUTKIMUSKESKUS VTT OY
Finland

Periodic Reporting for period 1 - NEXTBAT (Next generation technologies for battery systems in transport electrification based on novel design approach to increase performance and reduce carbon footprint)

Reporting period: 2023-06-01 to 2024-11-30

Summary of the context and overall objectives of the project

The NEXTBAT project aims to enhance the European battery ecosystem's global competitiveness. The project addresses the need to develop innovative, high-performance, and safe battery systems to support the electrification of transport and mobile applications. It focuses on reducing production costs and carbon footprint while increasing recyclability and interoperability. The consortium includes renowned research centres and SMEs, leveraging their expertise to develop safe-by-design battery systems.
The overall objectives are to develop battery systems with enhanced performance, including a 30-50% increase in energy/power density and a 25% reduction in battery weight using newly developed lightweight materials. The project also aims to increase battery lifetime, incorporating innovative electronic sensing/actuating systems. Two interoperable prototypes will be manufactured, and safety guidelines and methodologies will be established based on safety testing campaigns performed by certified laboratories and end-users. The project has also developed software for battery design, management, and optimizing manufacturing processes.
The project aims to increase the global competitiveness of the European battery ecosystem through generated knowledge and leading-edge technologies in battery materials, cell design, manufacturing, and recycling. The project also aims to boost the attractiveness of electrified mobility for citizens and businesses by offering lower prices, better performance, safety, and reliable operation. Additionally, NEXTBAT aligns with the EU Circular Economy Action Plan, aiming to increase overall sustainability and improve Life Cycle Assessment of the battery value chain.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

The NEXTBAT project has made significant progress towards its objectives during the first reporting period 6/2023-11/2024. The activities are mostly on track, and several key deliverables and milestones have been achieved as planned.
The project sourced and tested Gen3b and semi-solid-state cells, despite initial delays in cell selection. Safety testing at the cell level included crush tests, overcharge, short-circuit, and thermal stability tests. The design of two interoperable prototypes reached the final stages, focusing on high energy density and high power density. Innovative battery system architectures were developed, incorporating lightweight materials to reduce battery weight and enhance performance.
Significant strides were made in developing software for battery design, management, and optimization of manufacturing processes. This includes high-order modeling and simulation using HPC codes for immersion cooling and AI optimizations for battery management systems. The project incorporated BMS at the cell and system unit levels to increase battery lifetime by 20% at a State of Health of 80%. Development and initial validation of state of charge and state of temperature algorithms were completed.
Preparations for manufacturing the prototypes were initiated, including laser welding for battery tab connections and hybrid metal joining for the casing. Life Cycle Assessment and Life Cycle Costing analyses were started to map the supply chain and define the boundaries and objectives for the LCA study. Several key deliverables and milestones were achieved as planned, including the submission of reports on cell specifications, safety testing protocols, and conceptual battery system designs. The project is on track to meet its targets in the coming months, despite some delays in cell selection and market uptake tasks.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

The NEXTBAT project has achieved several results beyond the state of the art during the first reporting period.
1. Innovative Battery System Designs: The project is designing safe-by-design battery systems with increased performance, recyclability, and interoperability. The prototypes are in the final stages of design, and safety testing has been conducted at the cell level. The project has also made strides in developing software for battery design, management, and manufacturing.
2. Advanced Battery Management Systems: The project has incorporated innovative electronic sensing/actuating systems at the cell and system unit levels, increasing battery lifetime by 20% at a State of Health (SoH) of 80% at the cell level. The project has also developed software for battery models, high-performance numerical solvers, simulations, and optimization methods based on machine learning approaches and artificial intelligence techniques.
3. Safety Guidelines and Methodologies: The project has established safety guidelines and methodologies based on safety testing campaigns performed by certified laboratories and end-users. The project has also developed standardized safety assessment methodologies for battery systems.
4. Digital Twin and Virtual Design Tools: The project has evaluated a digital twin strategy, where the software package is structured with connectors to data and system actuators towards an optimal battery passport or digital representation for sustainable batteries. The project has also developed virtual design tools.
5. Life Cycle Assessment and Cost Analysis: The project has initiated Life Cycle Assessment (LCA) and Life Cycle Costing (LCC) analyses to map the supply chain and determine the boundaries and objectives for the LCA study. The project aims to increase overall sustainability and improve the Life Cycle Assessment of the battery value chain.
These results demonstrate the project's commitment to advancing battery technology and contributing to the global competitiveness of the European battery ecosystem.

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