Top News > Schneider Electric – Schneider Electric and Liminal partner to Enable High-Quality, Scalable EV Battery Production While Minimizing Waste

Schneider Electric – Schneider Electric and Liminal partner to Enable High-Quality, Scalable EV Battery Production While Minimizing Waste

January 23, 2025
Schneider Electric

Schneider Electric, the leader in the digital transformation of energy management and automation, today announced a partnership with Liminal Insights, a leader in battery manufacturing intelligence, to tackle critical challenges across the battery manufacturing industry, supporting the growing demand for EV batteries.  

 

Governments across the globe continue to put targets and legislation in place to phase out the sale of new internal combustion engine (ICE) vehicles. With global EV sales set to reach 40% in 2030, battery demand will jump tenfold in ten years. At the same time, EV battery manufacturers are struggling to scale their operations quickly while reducing waste. Currently, in mature battery factories, scrap rates range between 6% and 15% due to quality inadequacies being identified too late in the production process – scrap rates are significantly higher for new factories and new manufacturers. 

To address these challenges, Schneider Electric has strengthened its partnership with Liminal to develop a joint offering that integrates Liminal’s ultrasound-based metrology and analytics solutions with Schneider Electric’s automation and industrial intelligence ecosystem to deliver real-time inline quality inspection. The new integrated inspection solution – which is compatible with all battery cell types, including NMC, LFP, NCMA, Li-metal, solid state, and Na-Ion chemistries – offers battery manufacturers automated capabilities that enable identification of production deviations and real-time root cause analysis at the cell level.  

With enhanced ultrasound inspection and analytics, battery manufacturers can quickly identify and address production quality challenges before they escalate to product recalls, which cost the industry over $3 billion between 2020 and 2023. Initial tests for Liminal’s EchoStat inspection solutions suggest that a 1% reduction in scrap could save manufacturers an average of $10 million annually for a 10 GWh production block. Meanwhile, an eight-hour reduction in the cell-finishing process, enabled by enhanced operational efficiencies, could save up to $3 million annually for a 10 GWh production block.   

Key features of Liminal’s EchoStat ultrasound inspection solution include: 

  • End-to-End Automation and Integration – Leveraging Schneider Electric’s robust industrial automation alongside AVEVA’s software connectivity, this partnership enables the seamless integration of Liminal’s inspection systems within the broader manufacturing value chain, enhancing productivity and reducing quality costs.
  • Improved Operational Safety – Unlike traditional X-ray solutions, ultrasound inspection is radiation-free, eliminating the need for shielding, permits and specialized safety zones. This will simplify compliance while fostering a safer, more sustainable workplace.
  • Flexibility to Future-Proof Operations – The broad compatibility of the EchoStat solution enables manufacturers to standardize their inspection strategies and processes across different cell types. This flexibility enables manufacturers to easily adapt to new cell technologies as production needs evolve. The ability to inspect multiple cell types with a single solution also allows manufacturers to apply historical insights to future battery products.
  • Enhanced Efficiency and Performance – Liminal’s EchoStat ultrasound inspection systems are readily integrated in-line, require minimal floor space, and consume significantly less power than traditional CT and electrical quality test systems. Additionally, the latest innovation from Schneider Electric and Liminal provides real-time results. This enables faster decision making to increase cell production throughput and overall productivity, reducing operational costs and supporting sustainability goals.

“As battery manufacturers look to scale their operations, innovative technologies will be crucial to enhance operational efficiency and reduce costly battery scrap,” said Francois Verkindt Head of EV Battery Business, Mobility Segment at Schneider Electric. “Our ambition is to empower EV battery manufacturers to capitalize on the market opportunity but with the assurance of improved production quality, reliability and safety. We are delighted to bring further value to customers with this latest partnership with Liminal, following our successful collaboration with IN-CORE Systèmes to enhance efficiency and data connectivity in battery production.”

 

“Liminal’s mission is to catalyze the transition to electric vehicles and clean energy, both of which require greater supply of lower-cost, higher quality battery cells. Our partnership with Schneider Electric represents major progress for Liminal towards achieving this goal,” said Andrew Hsieh, Co-Founder of Liminal Insights. “By integrating EchoStat quality inspection data and analytics solutions with Schneider Electric and AVEVA’s factory intelligence ecosystem, we are able to deliver deeper insights and greater digital connectivity. This enables battery manufacturers to rapidly improve their quality, productivity, and efficiency.” 

 

SourceSchneider Electric

EMR Analysis

More information on Schneider Electric: See the full profile on EMR Executive Services

More information on Olivier Blum (Chief Executive Officer, Schneider Electric): See the full profile on EMR Executive Services

More information on Francois Verkindt (Head of EV Battery Business, Mobility Segment, Schneider Electric): See the full profile on EMR Executive Services

More information on AVEVA by Schneider Electric: See the full profile on EMR Executive Services

More information on Caspar Herzberg (Member of the Executive Committee, Chief Executive Officer, AVEVA, Schneider Electric): See the full profile on EMR Executive Services

 

 

More information on Liminal Insights: https://www.liminalinsights.com/ + Liminal is a battery manufacturing intelligence company that leverages the power of ultrasound and machine learning to deliver advanced insights that empower manufacturers. Our mission is to make electric vehicles the default option for any driver. By improving the performance, reliability and safety of batteries and decreasing their lifetime costs, Liminal is contributing to the scalability of e-mobility by empowering battery manufacturers to create a world where EVs are accessible to all drivers.

More information on Andrew Hsieh (Co-founder and Executive Chair, Liminal Insights): https://www.liminalinsights.com/company/leadership/ + https://www.linkedin.com/in/andrew-hsieh/

 

 

More information on IN-CORE Systèmes: https://www.incore-systemes.com/ + In-Core Systèmes is a leading technology company, whose expertise is concentrated around imaging systems and optical methods for 100% surface inspection of continuous processes.

The core activity of the company is to design and manufacture automatic surface inspection systems based on line scan cameras, high performance illumination and computer technology with its proprietary process software.

IN-CORE systems is located in Lyon area – France and was created in 1998 by the current directors, Christophe Pallas, Johnny Turkieh and Michel Popovic.

More information on Christophe Pallas (Managing Director, IN-CORE Systèmes): https://www.incore-systemes.com/

More information on Johnny Turkieh (Managing Director, IN-CORE Systèmes): https://www.incore-systemes.com/

More information on Michel Popovic (Managing Director, IN-CORE Systèmes): https://www.incore-systemes.com/

 

 

 

 

 

 

EMR Additional Notes: 

  • Lithium-ion Technology (Li-ion):
    • A lithium-ion (Li-ion) technology is an advanced battery technology that uses lithium ions as a key component of its electrochemistry. During a discharge cycle, lithium atoms in the anode are ionized and separated from their electrons. The movement of the lithium ions creates free electrons in the anode which creates a charge at the positive current collector. The electrical current then flows from the current collector through a device being powered (cell phone, computer, etc.) to the negative current collector.
    • Lithium-ion is the most popular rechargeable battery chemistry used today. Lithium-ion batteries power the devices we use every day, like our mobile phones and electric vehicles. Lithium-ion batteries consist of single or multiple lithium-ion cells, along with a protective circuit board.
    • Nickel Manganese Cobalt (NMC):
      • Nickel Manganese Cobalt (NMC) batteries belong to the family of lithium-ion batteries and are widely used in various portable electronics and electric vehicles. They are known for their high energy density, which allows for a compact and efficient energy storage solution.
      • A common type known for high energy density, suitable for high-performance EVs.
      • NMC batteries can achieve 1000 – 2000 charge-discharge cycles, while LFP batteries typically deliver 3,000 cycles or more. The higher cycle life means that LFP batteries will last longer, leading to reduced operational costs over the battery’s lifespan.
    • Nickel Cobalt Manganese Aluminum (NCMA):
      • NCMA batteries belong to the family of lithium-ion batteries and utilize a cathode material composed of nickel, cobalt, manganese, and aluminum, which offers a balance of energy density, stability, and cost compared to other lithium-ion battery chemistries.
    • Lithium Iron Phosphate (LFP):
      • LFP batteries belong to the family of lithium-ion batteries.
      • Lithium iron phosphate is a chemical compound LiFePO₄ or “LFP” for short.
      • Offers good safety, long lifespan, and cost-effectiveness, often used in more budget-friendly EVs.
      • LFP offers good electrochemical performance, low resistance and is one of the safest and most stable cathode materials available for lithium-ion batteries.
      • Lithium iron phosphate batteries offer lots of benefits compared to lead-acid batteries and other lithium batteries.
      • Longer life span, no maintenance, extremely safe, lightweight, improved discharge and charge efficiency, just to name a few.
      • LiFePO4 batteries are not the cheapest in the market, but due to a long life span and zero maintenance, it’s the best investment you can make over time
  • Sodium-ion Technology (NIB, SIB or Na-ion):
    • The sodium-ion battery, or NIB or SIB, is a rechargeable battery that uses sodium ions (Na+) as its charge carriers. Similar to lithium-ion batteries (LIB), the working principle and cell construction of SIBs can be relatively similar.
    • Emerging technology, uses abundant sodium, promising for cost-effectiveness and safety.
    • Sodium is 1000 times more abundant than lithium so the concept of sodium-ion (Na-ion) batteries is quickly moving from the laboratory to the real world.
    • Sodium-ion batteries provide energy efficient power with fast charging, stability against temperature extremes and safety against overheating or thermal runaway. On the other side, one of the major disadvantages of sodium-ion batteries is their relatively low energy density – the amount of energy stored relative to the battery’s volume. Lower energy density means bulkier and heavier batteries
  • Solid-State Batteries:
    • Solid state batteries operate the same way as any other battery. They take energy in, store it, and release the power to devices—from Walkmen to watches and, now, vehicle motors. The difference is the materials inside.
    • Currently under development, facing challenges with manufacturing and cost.
    • Lithium-ion batteries, used in EVs today, have a liquid electrolyte solution sandwiched in between their cathodes and anodes. Alternatively, solid state batteries use solid electrolytes.
    • The increased density means solid state batteries can hold anywhere between two to 10 times the capacity of a lithium-ion battery. The solid electrolyte in solid-state batteries has also a higher melting point and is less likely to burn, making it safer but the stability of these batteries is usually poor, and their high surface resistance limits their output and, concurrently, their applications and their manufacturing costs is very high.
  • Nickel-Metal Hydride (NiMH):
    • Older technology with lower energy density than Li-ion.
    • Primarily found in older hybrid vehicles.
  • Lead-Acid Batteries:
    • Oldest battery technology with low energy density and short lifespan. 
    • Primarily used in older or low-cost EVs, such as golf carts and some utility vehicles.

 

 

  • Kilowatt (kW):
    • A kilowatt is simply a measure of how much power an electric appliance consumes—it’s 1,000 watts to be exact. You can quickly convert watts (W) to kilowatts (kW) by diving your wattage by 1,000: 1,000W 1,000 = 1 kW.
  • Megawatt (MW):
    • One megawatt equals one million watts or 1,000 kilowatts, roughly enough electricity for the instantaneous demand of 750 homes at once.
  • Gigawatt (GW):
    • A gigawatt (GW) is a unit of power, and it is equal to one billion watts.
    • According to the Department of Energy, generating one GW of power takes over three million solar panels or 310 utility-scale wind turbines
  • Terawatt (TW):
    • One terawatt is equal to 1,000,000,000,000 watts.
    • The main use of terawatts is found in the electric power industry.
    • According to the United States Energy Information Administration, America is one of the largest electricity consumers in the world using about 4,146.2 terawatt-hours.