OnBASYS

Brief description 

The OnBASYS project aims to develop a safe and efficient battery energy storage system (BESS) that promotes the use of sodium-ion cells and integrates innovative technologies. At its core is an on-board battery management system (BMS) with electrochemical impedance spectroscopy (EIS), which enables precise real-time monitoring of the battery’s condition. This improves safety through early fault detection, particularly in the event of thermal anomalies. The use of sodium-ion cells offers a sustainable alternative with improved raw material availability and reduced fire risk. Additionally, AI-based algorithms are being developed to accurately estimate the state of charge (SOC) and state of health (SOH) to maximize diagnostic quality.

The project comprises several work packages, including market analyses, data collection, and the development of innovative diagnostic methods. A hardware-in-the-loop approach is used to validate the functionality of the BMS before it is integrated into physical systems. The results are expected to reach TRL Level 4 by the end of the project, with a focus on commercialization and the development of market-ready products in collaboration with industry partners. OnBASYS strengthens the competitiveness of the battery industry in North Rhine-Westphalia and contributes to a sustainable energy future.

The project is divided into four work packages:

WP1 first systematically assesses the market potential of sodium-ion battery storage systems for residential, industrial, and grid applications, evaluates trends, drivers, competing technologies, and regulatory requirements, and uses this information to develop a roadmap outlining maturity, production, and market access milestones; accompanying stakeholder workshops ensure acceptance and strengthen the concept’s competitiveness.

WP2 procures commercial Na-ion cells, subjects them to comprehensive electrical, thermal, and aging tests, and collects load profiles from the ACCURE database to obtain representative cycling data for algorithm development (WP3); all data is processed in a standardized manner; a teardown analysis provides insights for optimizing cell architecture and system integration.

AP3 aims to develop innovative diagnostic methods for sodium-ion batteries based on real-time EIS (online EIS) to precisely monitor the condition of battery energy storage systems and improve system integration.

AP4 integrates these advanced technologies into a modular, scalable sodium-ion BESS with an on-board BMS and EIS-based real-time monitoring, thereby improving fault prediction, safety, and service life, optimizing temperature management, and validating the solution through hardware-in-the-loop testing for commercial and industrial use.

OnBASYS is systematically translating its research findings into industrial applications. In collaboration with its SME partners ACCURE and SEINE Batteriesysteme, the project aims to bring sodium-ion cells - including a new battery management system - to TRL 4 by the end of the project. ACCURE will then integrate the diagnostic procedures into its cloud platform within 18 months and plans to offer monitoring services for approximately 1 GWh of battery storage starting about a year and a half after the project ends - at €600/MWh/year, this represents additional revenue of approximately €0.6 million/year, with long-term potential to increase tenfold. SEINE is simultaneously adapting its production and service processes to embed the technology into existing systems and enhance their safety and sustainability.

The results will be disseminated scientifically through journal articles and conference papers; at the same time, the consortium will evaluate patent applications and licensing models immediately after the project concludes. Within the first two years, at least two market-ready products or further developments are planned, as well as new R&D partnerships to build a competence network. In the longer term, OnBASYS aims for international contract research and the global rollout of the developed solutions. The first demonstrators are expected to be available just one year after the project’s completion, thereby paving the way for the next stage of integration of new cell chemistries and safety concepts. Overall, the project thus strengthens North Rhine-Westphalia’s battery value chain, positions the region as a technology leader, and contributes to a safe, sustainable energy future.