Multiscale Simulation Approach for Battery Production Systems

187 Pages·2017·10.297 MB·English

by  Malte Schönemann (auth.)

Sustainable Production, Life Cycle Engineering and Management
Series Editors: Christoph Herrmann, Sami Kara
Malte Schönemann
Multiscale Simulation
Approach for Battery
Production Systems
Sustainable Production, Life Cycle
Engineering and Management
Series editors
Christoph Herrmann, Braunschweig, Germany
Sami Kara, Sydney, Australia
Modern production enables a high standard of living worldwide through products
andservices.Globalresponsibilityrequiresacomprehensiveintegrationofsustain-
abledevelopmentfosteredbynewparadigms,innovativetechnologies,methodsand
tools as well as business models. Minimizing material and energy usage, adapting
materialandenergyflowstobetterfitnaturalprocesscapacities,andchangingcon-
sumption behaviour are important aspects of future production. A life cycle per-
spective and an integrated economic, ecological and social evaluation are essential
requirements in management and engineering. This series will focus on the issues
and latest developments towards sustainability in production based on life cycle
thinking.
More information about this series at http://www.springer.com/series/10615
ö
Malte Sch nemann
Multiscale Simulation
Approach for Battery
Production Systems
123
Malte Schönemann
Institute for MachineTools andProduction
Technology
Technische UniversitätBraunschweig
Braunschweig
Germany
ISSN 2194-0541 ISSN 2194-055X (electronic)
Sustainable Production, LifeCycle EngineeringandManagement
ISBN978-3-319-49366-4 ISBN978-3-319-49367-1 (eBook)
DOI 10.1007/978-3-319-49367-1
LibraryofCongressControlNumber:2016957861
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Foreword
Manufacturing companies play an important role in the transition to a global
sustainabledevelopment.Theycreateproductsbyusingresourcessuchasmaterials
and energy, which in return cause various emissions to the environment, and
directly or indirectly affect the well-being of people. Consequently, the goal must
be to improve the production operation to reduce costs and environmental impacts
while creating products with a desired quality. This isno easy task since prevalent
cause–effect relationships in production systems bear the risk of problem shifting.
In particular,this isrelevantfor theproductionof complexproducts which require
various processes, diverse equipment, and specific factories. Well-intended mea-
sures and the utilization of innovative technologies may lead not only to local
improvements, but also to undesired effects in other sectors or equipment of a
productionsystemcausinghigheroverallcostsandenvironmentalimpacts.Inorder
to avoid problem shifting, production engineers and product developers need
methodsandtoolsforanintegrateddecisionsupportandtofosterthecollaboration
ofthesedisciplinestogainaninterdisciplinarysystemunderstanding.Inthisregard,
simulationisapowerfulmethodwhichenablestoexaminethedynamicbehaviorof
complex systems. However, due to the high effort related to the creation and
employment of sophisticated simulation models, the application of simulation in
industry is so far limited.
With this published work, Schönemann has strongly contributed to the appli-
cation of simulation for planning and improvement of production systems and
products. He developed a multiscale simulation approach with an exemplary
application for the case of large scale battery systems production which considers
the relevant characteristics and elements of production systems needed for the
integrated evaluation of economic, environmental, and technological goals. His
approach is based on coupled simulation models allowing the utilization of
best-suited modeling approaches and tools to represent specific production system
elements in detail. As an example of a detailed model, he suggests an agent-based
process chain simulation in order to consider the characteristics and production
requirements of individual product units. This is novel in contrast to established
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vi Foreword
process chain simulation approaches. In addition, he defined interfaces between
different model types to enable the use of existing models and to increase the
re-usability of models, which reduces the effort for model creation and fosters the
collaboration of different disciplines and experts. Although being specifically
developed for battery production systems, the approach stands on a generalized
framework which allows an easy adaptation also to other industries.
Prof. Dr.-Ing. Christoph Herrmann
Technische Universität Braunschweig
Braunschweig, Germany
Prof. Dr. Sami Kara
University of New South Wales
Sydney, Australia
Acknowledgments
ThisbookistheresultofmyworkintheSustainableManufacturing&Life Cycle
Engineering Research Group of the Institute of Machine Tools and Production
Technology (IWF) at the Technische Universität Braunschweig. I specially thank
Professor Christoph Herrmann for providing a very friendly, productive, and open
working environment as well as for the great support regarding my thesis.
Furthermore, I thank Professor Sami Kara from the Sustainable Manufacturing &
Life Cycle Engineering Research Group of the University of New South Wales
(UNSW)inSydney,Australia,forhisgreatsupportandthecooperationwithinthe
JointGerman-AustralianResearchGroup,especiallyduringmyresearchstayatthe
UNSW.Moreover,IthankProfessorArnoKwadeforhispositivefeedbackandthe
evaluationofthisbook.AlsoIthankProfessorThomasVietorforthecoordination
ofthedissertationcommitteeandthegoodresearchcooperationduringthelastfew
years.
Many thanks go to all fellow colleagues in the IWF who made working at the
instituteapleasureandwhocontributedtogreatmemories.Inparticular,Iamvery
grateful to Sebastian Thiede and Denis Kurle for the detailed reviews of my work
and the great constructive discussions which helped very much in finalizing this
book.AlsoIthankJanBeier,GerritPosselt,andMariusWinterfortheuncountable
talks and their insightful comments. Thanks go also to Anne-Marie Schlake espe-
cially for helping a great deal with the publishing processes.
Moreover,IthankthecolleaguesfromtheBatteryLabFactoryBraunschweigfor
the great atmosphere. In particular, I thank Linus Froböse, Henrike Bockholt,
WolfgangHaselrieder,HenningDreger,andChristianeSchilcher,whohelpedmea
lot in understanding the battery production processes.
Special thanks go to Dirk Scharff, Roland Kossel, and Wilhelm Tegethofffrom
the TLK-Thermo GmbH for providing the TISC middleware software and the
required extensions. Without this support, it would have been very difficult to
demonstrate the applicability of my concept.
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viii Acknowledgments
Beyondthat,Ithankmyclosefriendsforallthegreatjourneys,adventures,and
trips which caused the necessary distractions. Niklas, Malte, Max, Alex, Nikos,
Meik, Conny, Sebi … it has been a blast!
Above all, I sincerely thank myfamily for always supporting my academic and
personal decisions with dedication and without hesitation. Thank you for every-
thing! And finally, lovely and deep thanks go to Anika for her patience, under-
standing, and unlimited support especially during the last few months of the
dissertation. Thank you so much!
Braunschweig, Germany Malte Schönemann
July 2016
Contents
1 Introduction.... .... .... ..... .... .... .... .... .... ..... .... 1
References.. .... .... .... ..... .... .... .... .... .... ..... .... 9
2 Battery Production and Simulation .. .... .... .... .... ..... .... 11
2.1 Battery Production ... ..... .... .... .... .... .... ..... .... 11
2.1.1 Batteries and Battery Components .. .... .... ..... .... 11
2.1.2 Production Systems and Production Management.... .... 15
2.1.3 Production of Battery Cells and Systems . .... ..... .... 18
2.2 Simulation of Production Systems .... .... .... .... ..... .... 24
2.2.1 Digital Factory ..... .... .... .... .... .... ..... .... 24
2.2.2 Simulation.... ..... .... .... .... .... .... ..... .... 25
2.2.3 Simulation in Production.. .... .... .... .... ..... .... 27
2.2.4 Multiscale Simulation .... .... .... .... .... ..... .... 28
2.2.5 Co-Simulation. ..... .... .... .... .... .... ..... .... 29
2.3 Summary and Preliminary Findings for the Simulation
of Battery Production. ..... .... .... .... .... .... ..... .... 31
References.. .... .... .... ..... .... .... .... .... .... ..... .... 32
3 State of Research for Multiscale Simulation of Production
Systems ... .... .... .... ..... .... .... .... .... .... ..... .... 39
3.1 Selection of Approaches and Definition of Evaluation Criteria.... 39
3.1.1 Selection of Approaches.. .... .... .... .... ..... .... 39
3.1.2 Evaluation Criteria .. .... .... .... .... .... ..... .... 40
3.2 Presentation and Evaluation of Existing Approaches .. ..... .... 43
3.3 Findings and Research Demand .. .... .... .... .... ..... .... 51
References.. .... .... .... ..... .... .... .... .... .... ..... .... 55
4 Multiscale Simulation Modeling Concept for Battery
Production Systems.. .... ..... .... .... .... .... .... ..... .... 59
4.1 Objectives and Requirements .... .... .... .... .... ..... .... 59
4.2 Modeling Framework Development ... .... .... .... ..... .... 62
4.2.1 System Boundaries and Scope . .... .... .... ..... .... 63
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