ZeroFailBattery

ZEROFAILBATTERY targets the critical "blind spot" in heavy-duty electrification by addressing the degradation of parallel-connected cells under real-world stress. We bridge the gap between academic theory and industrial reality by validating how large cell groups degrade under the chaotic loads and thermal gradients typical of heavy machinery.
Electrifying heavy machinery requires massive, parallel-connected battery packs, but current engineering faces two major roadblocks. First, the harsh reality of operating environments makes perfect cooling impossible, creating thermal gradients that cause uneven current distribution and accelerate cell failure. Second, the lack of accurate models forces OEMs to either over-engineer packs at great cost or risk catastrophic warranty failures. The industry urgently needs physics-based rules to "right-size" cooling and balancing systems.
We move from "guessing" to "knowing" by combining rigorous testing with advanced simulation. SEAMK subjects parallel cell groups to validated "Reference Dynamic Cycles" and induced thermal gradients using high-power cyclers to measure exact impedance divergence. The University of Oulu simultaneously develops a light digital twin, calibrated with physical data, to extrapolate degradation over a 10-year service life. These findings are finally verified on a full-scale "Mega-Module" retrofit to ensure scalability.
ZEROFAILBATTERY moves beyond theoretical studies to deliver concrete, exploitable engineering assets strictly defined by the project work packages. We produce a validated "Heavy-Duty Battery Design Guide" that provides SMEs and OEMs with physics-based rules for dimensioning cooling and balancing systems to prevent parallel group divergence. The project also releases a standardized "Reference Dynamic Cycle" and a calibrated Digital Twin capable of predicting battery degradation over a decade of service, validated against our real-world "Mega-Module" retrofit. Finally, we ensure broad industrial uptake through a public "Tech Tour" video series and a closing seminar that transfers this critical know-how directly to the Finnish heavy machinery cluster.