Simulation App Optimizes Electric Truck Battery Design and Lifetime
A collaborative project uses custom simulation apps to improve battery pack robustness and performance.
1The Long-Haul Battery Challenge
Electric delivery trucks face significant hurdles regarding battery longevity during long-distance highway travel. Current battery packs often fail to meet the durability requirements needed for efficient logistics operations. To address this, a consortium including Volvo Group and Resolvent launched the LaserBATMAN project to optimize battery robustness and overall service life.
2LaserBATMAN Project Scope
Initiated in May 2022 and concluded in May 2025, the project focused on the laser welding process used in battery manufacturing. Incorrect welding can lead to premature degradation of battery cells. The team aimed to analyze how these joining processes impact electrochemical performance and structural integrity within the battery pack architecture.
3Multiscale Modeling Approach
The engineering team utilized COMSOL Multiphysics to model battery performance from the individual cell level up to the entire pack. By inputting chemical reaction kinetics, they created a cell-layer model. This data was then used to train a deep neural network, creating a reduced-order model for rapid, accurate performance insights.
4Custom Simulation App Development
Resolvent developed a custom simulation app that functions as a specialized design tool for R&D departments. The app allows engineers to input specific pack geometry, cell counts, and operating conditions. It provides a user-friendly interface to test various charge-discharge profiles and ambient temperatures, streamlining the complex battery design workflow significantly.
5Busbar Weld Design Tool
A critical feature of the app is the Busbar Weld Design Tool, described as a tool within a tool. It enables engineers to calculate weld performance by adjusting parameters like weld shape, busbar thickness, and laser penetration depth. This allows teams to simulate production scenarios where welds might not reach optimal depth.
6Quantifying Design Tradeoffs
The simulation app provides deep technical insights that allow engineers to find the sweet spot in battery design. For instance, if the model suggests improved cooling, teams can potentially reduce the total number of battery cells while maintaining performance. This capability helps quantify the exact tradeoff between cooling systems and hardware setup.
7Predictive Performance Analysis
The app includes a Compute Battery button that visualizes weld temperature, state of charge, and solid-electrolyte interface layer thickness. Engineers can apply cooling flows to detect turbulence or standing air within the pack. These consistent analysis reports make it easier for cross-functional teams to share knowledge and optimize battery robustness.
8Impact on Green Logistics
By enabling more robust battery designs, the LaserBATMAN project supports the transition to sustainable long-haul trucking. The ability to predict and prevent failures through simulation reduces maintenance costs and carbon emissions. This collaborative effort demonstrates how advanced computational modeling can directly solve critical engineering challenges in the electric vehicle industry.