The Use of Big Data and Artificial Intelligence Should Not Be Regarded as Goals in Itself

Artificial intelligence (AI) is set to play a pivotal role in the European battery industry, with a focus on using data to deepen our understanding of products and production processes, and to control quality. This is a crucial step towards establishing stable and reproducible production procedures for battery cells in Europe.

Traceability is not a concern, thanks to existing product identification systems and automated data storage that enable digital cell records. The real challenge lies in leveraging these data to gain a deeper understanding of the product and production processes, and to ensure quality.

Reliable data on the capability of the manufacturing process is essential for stable production. Europe aims to establish cell production in the continent within five years, with quality being a key differentiator. The 'Quality Made in Europe' label is expected to become a promise for durable, high-quality, and sustainably produced batteries.

In the race for production capacity, quality assurance must be an integral part of the production process from the outset to ensure sustainable growth. To establish reliable testing processes when new technologies are constantly emerging, the characteristics that determine the quality of the end product must be identified during the development process, and stable testing and manufacturing processes must then be established for these characteristics.

Understanding fundamental terms like 'functional tolerance', 'machine and process variation', 'measurement uncertainty', 'acceptance limits', or 'intervention limits and error slip' is crucial for a stable production system. A consistent quality assurance concept is required throughout the entire value chain, including the systematic establishment of control loops with the targeted use of inline measurement technology, production-related tests, and laboratory analyses.

Calibrated measurement systems with proven measurement process suitability are necessary, often referred to as 'measurement system analysis' or 'MSA.' A stable and capable production system is created when product design, production process planning, and quality assurance work closely together. Active support from management is crucial.

During the ramp-up process, it's important to ensure the suitability of the measurement and testing processes as well as the capability of the production systems right from the start, even if this initially only involves preliminary machine performance based on low quantities. The critical characteristics in battery production, such as electrode coating tolerances, require a stable measurement uncertainty of less than one micrometer.

Studies show an average scrap rate of 30 percent during production ramp-up, and reducing this rate is a slow process, taking several years. However, Europe, with its strong machine and plant manufacturers, leading research institutions, and a deep understanding of quality and technology, is expected to catch up with Asia in cell design and production.

The most important European manufacturers planning to build competitive and independent cell production capacity in Europe within the next five years include major automotive and battery companies such as Volkswagen, Northvolt, and Mercedes-Benz, who are investing heavily in battery cell production facilities to ensure supply chain independence and competitiveness.

Test planning must be carried out by metrologically trained specialists and concluded with proof of the measuring process's suitability. The quality of the input data is just as crucial for AI models as it is for traditional quality assurance processes. Sensors and measurement systems must provide reliable, traceable data with low uncertainty.

AI-supported processes are becoming increasingly important in quality assurance, but classic analytical models can still be faster and more accurate in many cases. Dr. Philipp Jatzkowski, Senior Manager Quality Assurance Consulting at Testo Industrial Services, states that the challenges in battery cell production result from the complexity of the product, the production system, and the tight product and process tolerances. Testo Industrial Services sees its task as laying the foundations for quality assurance in battery production through accredited calibrated measurement technology, systematic test planning, and the consistent development of quality assurance strategies.

Most electrical measurements in battery production, such as voltage and insulation resistance, are not particularly challenging compared to the measurement of critical characteristics. However, the importance of maintaining a stable and reliable production system cannot be overstated, and the efforts being made by European manufacturers to achieve this are a testament to the commitment to quality and innovation in the industry.