Simulation App Speeds Up Electric Truck Battery Design

A consortium of industry partners and universities, including Volvo Group and the Technical University of Denmark, has developed a specialized simulation application to enhance electric truck battery longevity. The project, known as LaserBATMAN, utilized COMSOL Multiphysics to analyze how laser welding processes affect battery cell electrochemistry and degradation. By creating a multiscale model that transitions from individual cell behavior to full battery pack configurations, the team trained a deep neural network to optimize busbar tab design. This custom simulation tool allows R&D engineers to input specific geometric dimensions and operating conditions, such as temperature and charge-discharge cycles, to predict performance and robustness. The initiative aims to overcome the limitations of current battery packs, making long-distance highway travel for electric delivery fleets more feasible by improving overall battery life and manufacturing efficiency.