Flexible and scalable digital-twin platform for enhanced production efficiency and yield in battery cell production lines - BATTwin

锂离子电池是欧洲生态系统能量转换的基本组成部分。目前，欧洲在锂离子电池制造方面落后于亚洲，世界上90%以上的生产发生在中国、韩国和日本。为了克服这种情况，欧洲有一项雄心勃勃的扩建计划，到2030年将新建25家巨型工厂，预计价值350亿欧元。然而，在这些巨型工厂的升级阶段，预计会产生大量缺陷，在15%-30%之间。新的欧洲巨型工厂还将带来对1500亿欧元电池制造设备的需求。为了支持这一需求，欧盟生产设备行业需要填补目前的知识缺口，获得对亚洲供应商的竞争力，基于其在高科技、绿色技术方面的全球领先地位，并通过工业4.0数字解决方案，利用欧洲零缺陷制造模式。BATTwin的目标是通过开发一种新型的多级数字双胞胎平台来支持这一场景，以实现电池生产中的零缺陷制造，从而降低电池生产线的缺陷率。该解决方案集成了四个支柱，即(I)多传感器数据采集和管理层，通过数字电池护照数据模型得到数据语义的支持；(Ii)流程级数字孪生，通过多物理、数据驱动和混合方法对电极制造、电池组装和调节的关键阶段进行建模；(Iii)系统级数字孪生，基于模拟和分析建模；(Iv)以用户为中心、目标驱动的数字孪生工作流，增加数字孪生的可解释性，并推动用户进行系统设计和控制。该方法将在两个生产不同电池化学成分和几何结构的工业试点中进行测试，以验证该方法的灵活性和可伸缩性，从而实现欧洲零缺陷巨型工厂。

Li-ion batteries are fundamental components for the energy transition of the European eco-system. Currently Europe lags behind Asia in terms of Li-ion battery cell manufacturing and more than 90% of the world's production takes place in China, Korea and Japan. To overcome this situation, there is an ambitious ramp-up plan of 25 new gigafactories in Europe with an expected value of €35 billion by 2030. However, in the ramp-up phase of these Gigafactories, a massive production of defects is expected, between 15% - 30%. The new European Gigafactories will also bring demand for €150 bn of battery manufacturing equipment. To support this demand, the EU production equipment industry needs to fill the current knowledge gap and gain competitiveness towards Asian providers, grounding on its world-wide leadership in high-tech, green technologies, enhanced by industry 4.0 digital solutions, exploiting the European Zero Defect Manufacturing paradigm. The objective of BATTwin is to support this scenario by developing a novel Multi-level Digital Twin platform towards Zero-Defect Manufacturing in battery production, that will reduce defect rates in battery production lines. The solution integrates four pillars, namely (i) a multi-sensor data acquisition and management layer, supported by data semantics through a Digital Battery Passport data model, (ii) process-level digital twins, modeling the critical stages of electrode manufacturing, cell assembly and conditioning through multi-physics, data-driven and hybrid approaches, (iii) system-level digital twins, based on simulation and analytical modeling, (iv) user-centric, goal-driven digital twin workflows, increasing the explainability of digital twins and driving the user in system design and control. The approach will be tested in two industrial pilots producing different battery chemistries and geometries, validating the flexibility and scaleability of the approach towards Zero Defect European Gigafactories.