FOOD project: Forming optimization in battery cell production through diagnostic procedures and digital methods

Challenge

The cell finalization of lithium-ion batteries is one of the most notoriously resource-intensive steps in battery cell production. In addition to high demands on power consumption and system investments, this process directly impacts the performance, lifetime, and safety of the cells - and therefore on the overall quality of the finished product. Ensuring consistent quality is all-important, but traditional methods often fall short in predicting operational cell performance during production.

The FOOD project (Forming Optimization in Battery Cell Production through Diagnostics and Digital Methods), a collaboration between Fraunhofer FFB and ACCURE presents a way to overcome this challenge. Through the use of battery analytics consisting of digital methods and innovative battery diagnostic procedures, quality characteristics of the cells can be predicted at an early stage and process parameters can be adjusted to optimize both production efficiency and cell quality.  

Project goals

The FOOD project focuses on three key objectives:

1. Model-based cell grading

During production, cells are graded into categories as follows:

• A-quality

• B-quality

• C-quality

• Scrap

Conventional grading relies on a limited set of rudimentary features, which only give a rough approximation of the cells’ actual quality. The FOOD project introduces a much more sophisticated approach. By analyzing a diverse range of features with machine learning models, grading accuracy is significantly enhanced. This means higher precision in determining which cells are suitable for use and minimizing waste as well as warranty cases.

2. Reduction of end-of-line tests

Traditionally, end-of-line (EOL) tests have been necessary to obtain the information needed for cell grading—but it’s costly and time-consuming. By leveraging data collected earlier in the production process, the FOOD project enables accurate predictions of cell quality without relying on EOL tests, effectively rendering them obsolete. This reduces capital and operational costs while speeding up production timelines.

3. Formation process optimization

The formation process is another production step that is both critical to cell quality and also incredibly resource intensive. This step is essential to creating the solid electrolyte interphase that ensures cell stability. Developing a formation protocol that is quick without compromising cell quality is a challenging task. But the comprehensive quality monitoring developed within the FOOD project has made it possible to strike a balance between saving a lot of time and money, while maximizing cell quality.

Why It Matters

Battery production, especially at scale, is riddled with challenges, including energy inefficiencies, high costs, and maintaining consistent quality. The FOOD project’s innovative approach addresses these issues head-on by applying advanced analytics and diagnostics to key production steps. This not only enables early detection of flawed cells but also streamlines the entire manufacturing process, paving the way for cost savings and improved sustainability.

Key facts

The FOOD project is funded by the European Union

• Project duration: 01.08.2024 - 31.07.2027

• Funding amount: 1.194.545,34 €

• Funding code: EFRE-20800230, EFRE-20800232

• Partners: Fraunhofer FFB, ACCURE Battery Intelligence GmbH

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