Global EV sales are set to reach 40 per cent in 2030, leading to a tenfold in demand for EV batteries. Simultaneously, EV battery manufacturers are struggling to scale their operations quickly while reducing waste. Currently, in mature battery factories, scrap rates range between six per cent and 15 per cent due to quality inadequacies being identified too late in the production process. Scrap rates are significantly higher for new factories and new manufacturers.
To address these challenges, Schneider Electric and Liminal will develop a joint solution that integrates Liminal’s ultrasound-based metrology and analytics with Schneider Electric’s automation and industrial intelligence ecosystem to deliver real-time inline quality inspection.
The new integrated inspection solution – which Schneider Electric said is compatible with all battery cell types, including NMC, LFP, NCMA, Li-metal, solid state, and Na-Ion chemistries – offers battery manufacturers automated capabilities that enable identification of production deviations and real-time root cause analysis at cell level.
With enhanced ultrasound inspection and analytics, battery manufacturers can quickly identify and address production quality challenges before they escalate to product recalls, which cost the industry over $3bn between 2020 and 2023.
Initial tests for Liminal’s EchoStat inspection solutions suggest that a one per cent reduction in scrap could save manufacturers an average of $10m annually for a 10GWh production block. Meanwhile, an eight-hour reduction in the cell-finishing process, enabled by enhanced operational efficiencies, could save up to $3m annually for a 10GWh production block.
In a statement, Francois Verkindt, head of EV Battery Business, Mobility Segment at Schneider Electric, said: “As battery manufacturers look to scale their operations, innovative technologies will be crucial to enhance operational efficiency and reduce costly battery scrap.
“Our ambition is to empower EV battery manufacturers to capitalise on the market opportunity but with the assurance of improved production quality, reliability and safety. We are delighted to bring further value to customers with this latest partnership with Liminal, following our successful collaboration with IN-CORE Systèmes to enhance efficiency and data connectivity in battery production.”
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