Digitalized threads stitch batteries into value-chain tapestry

The threads of digitalization have already ensnared sensors, drives, I/O, motor control centers, PLCs and other control devices in their networks, and now they’re coming for former peripherals on the edges. Here’s looking at you power supplies, transformers, monitors—and batteries.

“The digital thread creates a network of interconnected platforms, but it’s a moving target,” said Steve Nguyen, digital services sales executive at Rockwell Automation, during the battery industry panel discussion at Automation Fair 2024 last week in Anaheim, Calif. “The digital thread presently has four parts, including e-platforms like manufacturing execution and enterprise resource planning systems, fiber-optic and other networking formats, optimization platforms, and people who can interact with other sections of the thread and each other.”

Stephanie Van Kirk, battery subject matter expert at Rockwell, added that establishing a digital thread for battery manufacturing is helpful because, “This field is pretty dynamic, there’s no such thing as standardization, and there are many different designs, logic and packages of battery cells and finished products. Designing and establishing a digital thread could help identify metrics and minimize defects, while adding tools like machine learning (ML) and artificial intelligence (AI) could further optimize manufacturing.”

Passports streamline thread travel

Doug Johnson-Poensgen (pictured), cofounder and CEO at Circulor, which provides supply chain visibility, reported the value chain and digital thread for battery manufacturing extends from mined resources to materials undergoing physical processes that turn them into products to secondary uses and recycling. He added that digital passports can also identify the scope of recalls more quickly and reduce their costs.

“Digital tags and passports for identifying materials and products have been added at almost every stage to track them as they move and trace them as needed later,” said Johnson-Poensgen. “This and other types of documentation were made necessary by the recent adoption of regulations, such as the European Union Battery Regulation (EUBR) and the European Union Deforestation Regulation (EUDR), which require digital passports and documentation for a range of products, so customers will have more details about the products they buy.”

Because initial battery manufacturing processes involve a lot of chemicals and separation processes to produce cells, VanKirk reported it helps if manufacturers are able to look back at their applications, identify and track inefficiencies and increase supply-chain transparency. “Particle size distribution can affect battery quality, but technology has evolved that lets users evaluate these issues and apply predictive analytics,” said Van Kirk. “Also, using digital passports, lifecycle management, and end-of-life and recycling options further optimizes design and production.”

Digital twins adjust tire extrusions

To give digital threads for battery manufacturing some much-needed assistance, Steve Nguyen, digital services sales executive at Rockwell, reported that digital twin models and simulations can help in two main areas.

“First, a virtual representation of a material flow can help optimize it,” explained Nguyen. “For example, Rockwell recently worked with a solar panel company that wanted to identify bottlenecks and improve overall equipment effectiveness (OEE) by about 5%. But after a minimal study and expansion, it improved OEE by 15%. It also created a ‘golden facility’ digital twin, which could be reproduced, dragged and dropped, and customized where needed.”

Secondly, Nguyen reported that digital twins can improve quality-flow optimization. For instance, extrusion processes in the tire manufacturing industry focus on the risks associated with establishing and maintaining proper weights and tolerances. This was previously a very manual process, but it has shifted to being more autonomous. “The goal in tire extrusion is to find and settle on the right chemistry,” added Van Kirk. “This makes it easier for users, including small manufacturers, to identify and make iterative adjustments, get to market quicker, and help future-proof their processes.

Toughening supply and value chains

Because battery manufacturers are being asked by their consumers to ensure better sources of materials, components and data, Johnson-Poensgen reported they’re having to think of better ways to trace their original sources because they’ll be at a disadvantage if they don’t. However, Nguyen stated the best way to strengthen supply and value chains is not to start tackling all their digital threads right away with a big spend.

“It’s better to start small, and with best cases and inefficiencies where you can have the most impact,” explained Nguyen. “You start with data gathering, identify gaps, implement predictive maintenance and quality, and reanalyze and adjust as needed.”

Johnson-Poensgen added that, “Battery manufacturers are trying to identify all the players in their supply chains, but they also run into resistance and obstacles. In some cases, it’s easier to work with neutral third parties.”

Van Kirk pointed out the biggest obstacles in battery manufacturing are typically costs related to capital expenditures for infrastructure. “Manufacturing complexity is also a challenge due to a lack of standard chemistry for tires,” she said. “This is why manufacturers need more detailed contexts, so they can make better use of available data.”

To coordinate and strengthen these approaches, Jamie Nelson, battery ecosystem sales director at Rockwell, reported it’s never too early for system integrators, engineering procurement contractors (EPC) and their manufacturing clients to get their automation vendors involved in designing, specifying and setting up their processes, so they can begin making their best possible products sooner.

“Rockwell itself has 20 different manufacturing facilities, which make PLCs and all our other products, and we’ve been digitalizing for 20 years,” said Nguyen. “Consequently, we can show other manufacturers how to build contextualized, data-driven applications that are truly valuable, without the trial-and-error process of ‘throwing spaghetti on the wall’ for three or four months and seeing what sticks. We can’t see patterns in uncontextualized data, so setting up and correcting information is where digital threads prove their value.”