Multiperspective Optimization of Cell and Module Dimensioning for Different Lithium‐Ion Cell Formats on Geometric and Generic Assumptions

The main challenge in developing electric and electrified vehicles is the drivetrain with the associated battery system. Within the battery system, individual modules consisting of multiple interconnected battery cells provide the engine with power and energy. A crucial part of developing the electric vehicle's battery is the optimized dimensioning of modules and cells. Therefore, designing a unified cell format may be a competitive advantage for original equipment manufacturers in rapidly changing market situations. Different constraints, such as peculiarities of different battery formats, module sizes, or required module voltages must be evaluated for optimized battery cell dimensioning. Herein, a holistic cell‐module optimization based on geometric and generic assumptions is provided. The presented model considers various factors like cell format‐dependent geometries and their limits, cell‐size specific cell‐to‐cell stacking distances as well as module geometries and voltage requirements. An application‐dependent energy and cost perspective analysis resulting in a user‐defined weighting model to optimize the cell format and its corresponding dimensions are investigated. Furthermore, the optimized module dimensioning for prior‐specified cells is introduced. Pareto‐optimal results within this analysis are discussed and enable the generic cell‐module optimization to be used in higher integrated battery system optimization models. Herein, battery cell and module dimension optimization is performed based on prismatic and pouch format lithium‐ion battery cells. Cost and energy‐specific perspective analyses are evaluated with a generic, geometric‐derived cell, and module model. The model's modular structure enables interchangeability in its individual submodels of cell and module sizing limits, cell stacking, and cell costs.