Battery engineering

You can leverage a comprehensive digital twin from Siemens Digital Industry Software to optimize battery design from cell to pack. This allows engineers to simulate and test various design iterations in a virtual environment, optimizing performance, thermal management, and structural integrity without extensive physical prototyping. You can validate designs early using model-based simulations, reducing time-to-market and costs. Moreover, a cross-domain collaboration environment integrates chemistry, mechanical, and software teams to ensure seamless design coordination. Finally, our requirement driven product development solutions help balance critical factors such as safety, energy density, and manufacturability faster and with complete traceability.

Siemens’ Simcenter portfolio offers advanced simulation tools that accurately predict and optimize the thermal management of EV batteries. By modelling the interaction of thermal, electrical, and mechanical subsystems, Simcenter helps ensure that batteries operate within safe temperature ranges, preventing overheating and thermal runaway. Simcenter's integration with CFD technologies enables precise analysis of cooling strategies and energy efficiency, ensuring enhanced performance, longer battery life, and overall vehicle safety under real-world conditions.

A battery management system (BMS) continuously monitors performance, balances cell voltages, and ensures the battery stays within its safety limits. With Siemens’ end-to-end connected workflow, collaboration across cell engineers, control algorithm developers, and embedded software engineers is streamlined. The approach leverages system simulation to validate BMS behaviour at all stage of the development. Moreover, the software development process is following best practices which ensure ISO26262, autosar and cybersecurity compliance. This integrated and model-based approach accelerates defect-free development and secure validation of BMS software, ensuring faster, reliable results while meeting safety, security and performance standards.

A battery cell is the fundamental building block of a battery, where chemical energy is converted into electrical energy through electrochemical reactions. Each cell typically consists of an anode, cathode, electrolyte, and separator, working together to generate a specific voltage and capacity. In modern applications, cell chemistry—whether lithium-ion, solid-state, or beyond—plays a pivotal role in determining energy density, safety, and cycle life. For manufacturers, optimizing cell performance while reducing costs is crucial, as advancements at the cell level directly impact battery efficiency and overall market competitiveness. The future of energy storage hinges on breakthroughs in cell chemistry and design.

A battery pack is a collection of individual battery cells assembled to deliver the desired voltage and capacity for a specific application. Beyond just combining cells, it involves intricate design, thermal management, and Battery Management Systems (BMS) to ensure safety, longevity, and performance. In high-demand sectors like EVs and energy storage, optimization of pack density, cooling mechanisms, and charge cycles are critical to push the boundaries of energy efficiency. As battery technology evolves, pack design becomes a key differentiator in reducing costs, improving range, and accelerating the electrification of industries. For manufacturers, the challenge is balancing innovation with scalable, cost-effective production.