Simulation in battery production
Reliable planning for complex production and logistics processes
The industrialisation of electromobility poses enormous challenges for companies. In battery cell production, battery assembly and the manufacture of electric drives, highly complex production processes meet demanding logistics structures. At the same time, investment volumes are high, technologies are developing rapidly and the variety of variants is constantly increasing.
Under these conditions, sound planning is crucial. This is precisely where process simulation demonstrates its added value.
Holistic view of the value chain
Simulation enables the realistic mapping of complete value chains. From cell production to module and pack assembly to internal logistics, processes can be modelled and analysed based on data.
In cell production, this includes process steps such as mixing, coating, calendering, notching, stacking, cell assembly, formation and ageing. In addition, material flows, buffers, conveyor technology and clean and dry room logistics can be realistically represented. Temperature-controlled and thermally separated storage and intermediate areas can also be taken into account.
In assembly and drive technology, simulation supports the design and comparison of layout variants. Logistics processes, quality assurance, type changes and automated transport systems can be evaluated at an early stage. Production and testing processes in rotor and stator manufacturing can be specifically decoupled and secured.
Transparency regarding throughput, utilisation and bottlenecks
A key benefit of simulation is transparency. Based on real process and layout data, reliable forecasts are made regarding output, availability, throughput times and fill levels.
Companies receive answers to crucial questions:
- Where do bottlenecks occur in the production flow?
- How do cycle time changes or variants affect the overall system?
- What buffer sizes are necessary?
- How many operating resources such as workpiece carriers, AGVs or tugger trains are actually needed?
Dynamic modelling allows variants, capacities and scenarios to be flexibly adapted and compared with each other. This creates planning reliability in an environment characterised by uncertainty and high complexity.
Securing investments and ramp-up
The introduction of new production lines or entire plants involves considerable investment. Wrong decisions in the layout or dimensioning of plants and logistics systems have a long-term impact on productivity and costs.
Simulation helps to secure layout, investment and control decisions at an early stage. Different scenarios can be run through and evaluated as early as the concept phase. In later project phases, the model can be further developed up to virtual commissioning.
Another advantage is the reduction of start-up and ramp-up times. Potential weak points are identified before they occur in real operation. This enables a more stable production ramp-up and reduces the risk of costly rework.
Safety and supply chain in focus
In addition to production and logistics processes, safety-related processes can also be analysed. Handling high-voltage components, hazardous substances and thermally sensitive materials places special demands on processes and infrastructure.
Furthermore, overarching supply chain issues can be integrated into the simulation model. Special processes such as battery tray production, cell disassembly or painting can also be examined and evaluated.
Simulation as a decision-making tool
Simulation is more than just a technical analysis tool. Realistic animations and model-based evaluations create a common understanding of processes across departments. The model serves as a communication tool between planning, engineering and operations.
As a manufacturer-independent partner, we support companies from the initial idea through layout and control planning to the virtual validation of complex production systems. The aim is to provide an objective and reliable basis for decision-making for sustainable investments in battery and drive technology.
The increasing complexity of electromobility requires structured and data-based planning. Simulation creates transparency, reduces risks and helps to design robust production and logistics systems right from the start.
