As express delivery demands faster turnaround and higher vehicle utilization, battery reliability has become a critical factor in long-haul electric trucks.
A case study by COMSOL describes how Volvo Group Trucks Operations, Aurobay, Resolvent, and Technical University of Denmark collaboratively developed a simulation application under the Multiscale Simulation of Laser Welding for Optimal Battery Pack Manufacturing project (LaserBATMAN, 2022–2025), with funding and support from Vinnova and the European Commission, to address battery lifetime challenges in long-haul electric trucks.
The application integrates multiscale modeling of laser welding with battery electrochemistry, linking manufacturing parameters to pack-level behavior. It allows engineers to:
- Define pack geometry, operating conditions, and charge–discharge cycles
- Evaluate busbar weld design (e.g., shape, thickness, penetration depth)
- Predict temperature, state of charge, and solid–electrolyte interface (SEI) layer growth associated with degradation
- Analyze the impact of cooling strategies on performance and cell configuration
By packaging the coupled welding and battery models into a usable application, the approach aims to let engineers directly test how weld design, operating conditions, and cooling strategies affect temperature, degradation, and pack configuration early in the design and development process of batteries.
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