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Simulation App Optimizes Electric Truck Battery Design for Lifetime and Robustness
Key points
- Simulation app developed for electric truck battery design.
- Optimizes battery lifetime and robustness.
- Focuses on laser welding in manufacturing.
- Project involved Volvo, Resolvent, and universities.
Addressing Electric Truck Battery Challenges
Companies are adopting electric trucks to reduce fuel costs and emissions in delivery fleets. A key challenge for long-distance electric trucks is the limited lifetime of current battery packs. This limitation makes extended highway travel difficult for these vehicles.
Multiscale Simulation and Custom App Development
To overcome battery lifetime issues, a consortium of universities and industry partners implemented multiscale simulation and a custom simulation app. The organizations involved included Aurobay, Resolvent, the European Commission, the Technical University of Denmark (DTU), Vinnova, Innovation Fund Denmark, and Volvo Group Trucks Operations.
Resolvent, an engineering consultancy, developed the simulation app. This app allows Volvo's R&D department to test battery lifetime performance efficiently.
The LaserBATMAN Project
The project, named "LaserBATMAN" (Multiscale Simulation of Laser Welding for Optimal Battery Pack Manufacturing), ran from May 2022 to May 2025. Its primary goals were to optimize battery pack robustness and lifetime.
Laser welding, used for connecting battery cells (e.g., via a busbar), significantly impacts both metrics. Correct laser welding can extend battery life, while incorrect welding can lead to degradation. Computational modeling is used to analyze and predict the effects of these welding processes.
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Reporting from
A consortium including Volvo Group Trucks Operations and Resolvent developed a simulation app to optimize electric truck battery packs. The app, part of the LaserBATMAN project, helps improve battery lifetime and robustness by simulating laser welding processes. This development addresses the challenge of battery longevity in electric heavy-duty vehicles.