Battery improvement from prototype to recycling

Battery development from prototype to recycling

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Bertrandt combines the various services and competencies of its technical units to enable zero-emissions driving. Experience ranges from design and planning to the concept of end-of-life for high-voltage batteries.

This technology has been validated at the High Voltage Battery Test Center – from modules to hybrid to EV batteries.

(Photo: Bertrandt)

As a development services provider (EDL) in the automotive, aviation and mechanical engineering sectors, Bertrandt focuses on technology-oriented services for today’s and future mobility. Digitalization trends, autonomous systems, networks and electric mobility play a central role here.

With nearly 50 years of experience in various fields and a global presence, EDL is able to quickly and efficiently develop customer-centric solutions. The company sees the ability to implement projects holistically as an asset – from consulting to implementation and protection to moving production and after sales, as well as in the speed with which projects can be scaled up. Customer challenges are addressed by approximately 12,000 employees in more than 50 locations around the world.

The complete battery life cycle at a glance

Four Bertrandt divisions contribute their skills and services to the entire battery life cycle.
Four Bertrandt divisions contribute their skills and services to the entire battery life cycle.

(Photo: Bertrandt)

The way experts from different fields bring their skills together is evident from performance throughout the entire battery life cycle: individual components such as raw materials, cell, unit, and battery pack are each considered, as well as individual steps of the life cycle – from development to production, and operation in the first application. , and further use with remanufacturing and operation in other applications until reuse through recycling.

The individual services of the units contribute to the different phases of the life cycle. As the leading unit for high-voltage battery development, the “eMobility Systems” unit forms the core and backbone of the entire development of electric mobility. By doing so, it contributes its own component and system expertise from the battery cell and modules to the system design and integration. From the “Software Experts” module, the client receives software solutions from applications and back-end solutions (such as the “GUIDE” innovation suite) to data science applications. With these software solutions, it is possible to control and manage the battery life cycle, but also to analyze and improve it. Autonomous Mobility and Information Systems provides connectivity solutions for obtaining production data or over-the-air updates and user interfaces as part of HMI/UX applications.

This is how Bertrandt charts the life cycle of the battery in his institution.
This is how Bertrandt charts the life cycle of the battery in his institution.

(Photo: Bertrandt)

The Design Solutions unit is responsible for the development of the battery housing and the vehicle integration concepts in general. With their many years of experience, the experts from the Simulation Solutions unit cover all simulated load situations – from classic operating durability and vehicle safety to specific battery load situations, for example in the field of thermal management. In the “Integration Services and Engineering Management” module, not only project and quality management competencies are aggregated, but also increasingly centralized services for determining CO2Emissions, life cycle assessment and so-called circular economy requirements until homogenization.

All relevant environmental and durability simulations can be performed in the Test Solutions module on a test area of ​​more than 44,000 square metres, which was introduced last year using the example of an electronic mast. Test facilities and specific competencies for electrical mobility are the focus of eMobility Test Solutions and are expressed, among others, in the two high voltage test centers, electronic hub test bays and inverter test benches. The range of services offered by the Vehicle and Prototyping Services unit includes the creation of battery prototypes down to small series, the construction and conversion of battery electric test vehicles and full vehicle testing, as well as the professional disposal of vehicle testing and batteries. In the Powertrain Solutions module, the focus is on rangefinding on the chassis dynamometers of the Bertrandt Center for Powertrain Solutions.

Which supports the planning of production facilities for battery and components, supplier management and solutions to implement CO2The neutral production you are looking for, “Smart Production Solutions” is the right place for you. The “Aftersales and Next Media Solutions” area concludes Bertrandt’s network portfolio with offerings along with expanded digital business models for clients as well as qualifying workshops. Bertrandt also brings this knowledge to the future workshop as a partner.

development examples

The “Scalable Battery Platform” demonstrates an innovative concept of the battery module of the future, which was developed in collaboration with steel specialists from Voestalpine. It includes services from the areas of battery development, design, production and production planning, which are combined with simulation and test results as well as sustainability requirements. The successful interaction between the fields of electronics development, housing development, testing and construction has been used by Mercedes-Benz Trucks. Bertrandt played a major role in developing batteries for the E-Actros. Solutions to the topic of sustainable mobility of the future presented in the “HARRI” innovation platform were awarded the German Innovation Award in 2020.

(No.: 48261549)

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