Fraunhofer Research Institution for Battery Cell Production FFB
Fraunhofer Research Institution for Battery Cell Production FFB

QUGAPP

Predictive quality gates and sustainability assessment in battery cell production and module and pack assembly

Brief description

A cell-accurate transfer of process and quality data from production and the integration of (PQ) in quality gates along the entire battery production process through to the end application (Figure 1) should enable a reduction in the inspection effort in the area of incoming and outgoing goods inspection in the battery value chain.

The main objective of the project is to reduce physical inspection scopes in the battery value chain by up to 80%, especially for incoming and outgoing goods inspections in module and pack assembly. The physical inspections at quality gates are to be eliminated by developing a trustworthy PQ model that achieves TRL 7 as part of the project. The necessary database will be created using a suitable traceability system. In addition, the derivation of sustainability indicators from already collected process and quality data is to be made possible and their presentation and optimization implemented using an online process model.

Figure 1: Target image of the research project

Cross-process chain traceability enables predictive quality and sustainability assessment

Schedule

The work timeline is divided into eight work packages:

WP1: Requirements and Application Scenarios: Definition of requirements from QUGAPP for the overall process chain and identification of deployment points in the module and pack assembly of battery production.

WP2: Influence and Relevance Assessment of Process and Quality Parameters: Creation of a catalog with qualitative evaluations of the relationships between process and quality parameters, along with a methodology box for the quantitative analysis of these relationships.

WP3: Predictive Quality Models: Development of Predictive Quality models, including metrics to quantify the reliability.

WP4: Development of a Traceability System: This work package focuses on conceptualizing the physical and digital components of the traceability system.

WP5: Sustainability and Certifiability: Systematic and data-driven evaluation of sustainability and certifiability through the holistic integration of existing data sources along the process chain.

WP6: Recommendations for Process Optimization: Development of action strategies for optimizing (production) processes and sustainability, including the reduction of physical testing in module and pack assembly.

WP7: Integration, Application, and Validation: Validation of project results based on application scenarios, as well as external presentation of the project results.

WP8: Project Management, Documentation, and Transfer of Results

Utilization of results

This project generates synergies between the topics of traceability, predictive quality, sustainability assessment and a general understanding of processes from battery cell production through module and pack assembly to the end user's incoming goods inspection, thereby generating significant added value compared to isolated solutions. On the one hand, the holistic approach ensures applicability in the industry. On the other hand, added value is also created for companies that only cover part of the process chain. The knowledge of the upstream and downstream process steps can be used to optimize and standardize incoming and outgoing inspections in the long term.

The transferability of the results to ongoing and planned research projects represents an important component of scientific and technical utilization. The FFB is a scaling and exchange platform in accordance with the umbrella concept of battery research production. The existing, far-reaching network of the three research institutes in industry and research ensures the establishment and further development of the project results. In particular, the institutes address the scientific aspect by publishing research work at conferences and in specialist journals and, in the medium term, feed results back into self-organized teaching (WZL) and in seminars for the training of young scientists.

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