A novel Zero-Defect Manufacturing approach for defect reduction in battery production

Li-ion batteries are fundamental components for the energy transition of the European ecosystem. Currently, Europe lags behind Asia in terms of Li-ion battery cell manufacturing, over 90% of the world's production takes place in Far East. To overcome this situation, there is an ambitious ramp-up plan of 25 new gigafactories in Europe with an expected value of €35 bn by 2030. However, during the ramp-up phase it is expected that a significant amount of deffective batteries and scrap, estimated between 15%-30%, will be generated due to the lack of knowledge-based methods for production quality improvement in the battery sector. This paper presents the innovative features of the Zero-Defect Manufacturing approach for battery production lines proposed by the BATTwin project. The solution encompasses four interconnected layers: (i) a multi-sensor data acquisition and management layer, supported by data semantics through a Digital Battery Passport compliant data model; (ii) process-level dig...