Hybrid testing & multi-physics simulation for faster, safer batteries

Background

Qualifying a new battery pack typically requires a year of cell testing under dozens of conditions, followed by module and pack validation. Safety assessment relies on destructive thermal runaway tests, which are expensive and hard to repeat for every new design, chemistry or ageing state. For an industry under strong cost pressure, this slows development and weakens competitiveness.

About the project

ACCELERATE replaces part of the physical testing with validated computer models. The models are calibrated with targeted experiments and then used to explore designs and operating conditions virtually. The project develops ageing and safety models from cell to pack level, uses AI to reduce the number of tests needed, and contributes to European standards and the Digital Battery Passport. The aim is to shorten battery development by 12–18 months.

RISE's role

RISE leads the work on thermal runaway modelling and safety. Building on our fire and abuse test facilities and experience in fire modelling, RISE will:

• Create an open dataset of thermal runaway parameters for battery cells
• Model how thermal runaway spreads in battery modules, including gas venting and fire
• Speed up simulations with simplified models and AI
• Develop a fast AI-based model for real-time battery safety predictions

The results will help industry and authorities judge when virtual methods can replace physical thermal runaway tests, and support safer handling of damaged and aged batteries.