Digital twins to give electric car batteries a second life

With the help of digital technology, the Circul8 project aims to create new opportunities for the second life of batteries, long after they have left the roads. Niclas Ståhlbom is a PhD student in industrial systems at MDU and is investigating how digital technology can extend the lifecycle of batteries.

Electric car batteries still have a lot to offer when they no longer meet the requirements for use in vehicles. Most electric car batteries are taken out of service when the battery has only lost 20 to 30 percent of its capacity. The Circul8 project is investigating and developing digital solutions that enable reuse, refurbishment, and resale of batteries. An important component is what is called digital twins; digital copies of physical objects, which in this case reflect the battery's condition and usage.

We want to use digital technology to find and optimize new uses for batteries, such as energy storage. In this way, we can give the batteries added value and extend their lifespan, contributing to the green transition, says Niclas Ståhlbom.

The project is run together with several industry partners, which is important in this type of research. One of the biggest challenges so far has been managing the complex and sensitive issue of data security.

"It's not just about extracting and using industrial data, the data has great value for the companies and they hold on to it tightly. Collaboration is therefore crucial for the research. It requires flexibility and understanding of each party's needs. Fortunately, there is good documentation and knowledgeable contacts at the companies that facilitate cooperation," says Niclas Ståhlbom.

In addition to technology, business models also play an important role. Uncertainties about the status and quality of used batteries are a barrier to a circular market. Niclas Ståhlbom believes that the combination of digital forecasts and upcoming EU regulations for so-called battery passports will increase trust in the market.

The project is fully in line with MDU's vision of creating high-quality research through collaboration that contributes to a sustainable future. By reducing the need for new batteries and thus also extraction, manufacturing, and waste, Circul8 promotes a circular economy.

Within the next decade, a large number of electric car batteries will reach the end of their first life. Thanks to MDU's research, the future looks bright for battery reuse. It is a development that can have a significant impact, not only in Sweden but globally.

The most exciting thing about this project is that it is a relatively new research area with great potential. The idea that our digital models will be used internationally is very inspiring. It feels incredibly rewarding to be able to contribute to something that has a real impact both in industry and research, says Niclas Ståhlbom.

Research area DigiCircle

The project is carried out within the Digital and Circular Industrial Services research area:

Digital and Circular Industrial Services (DigiCircle) External link.

Niclas Ståhlbom is one of the researchers in the Knowledge Foundation (KKS) Synergy project, Circul8 (Smart Battery Circularity).

Circul8