Improving Battery Safety with Digital Twin Technology

As part of the NexTwin project, we are developing a digital twin—a virtual model of a battery system that allows us to better understand, predict, and improve battery safety.

Identifying Safety Risks at the Material Level

We begin by studying the key components of a battery to understand where safety risks can arise:

• The anode (negative electrode): We analyze how sodium metal behaves during operation, including the formation of unwanted structures or gaps that can lead to short circuits or performance loss.

• The solid electrolyte: We investigate how stable and mechanically robust this material is under different conditions, as its failure could compromise the entire battery.

• The cathode (positive electrode): We examine how the sulfur-based cathode reacts during charging and discharging, including how changes in its chemistry may affect stability.

By understanding these processes, we can identify the conditions that may lead to degradation, failure, or unsafe operation.

Combining Experiments with Advanced Modeling

To ensure reliable predictions, we combine scientific data with targeted experiments. These include testing battery materials, analyzing aged or damaged cells, and using advanced imaging techniques to detect structural weaknesses. This allows us to capture how safety-critical issues develop over time and under real operating conditions.

Predicting Safety at the Cell and System Level

We integrate all findings into a comprehensive digital model of a battery cell. This model allows us to simulate how batteries behave under different stresses—such as high current, temperature changes, or long-term use—and to predict potential safety risks before they occur.

We then scale this approach up to entire battery systems, including large energy storage units. This enables us to evaluate how batteries perform in real-world scenarios, such as integration with renewable energy sources, and to assess risks at the system level.

Safer Batteries for a Sustainable Future

Our digital twin approach helps us detect potential safety issues early, reduce the risk of failure, and design more robust battery systems. By improving safety at every level—from materials to full-scale applications—we are contributing to the development of reliable energy storage solutions that support the transition to a clean and sustainable energy future.