The Grid 7 SIMULATION E-Mobility Engineering | May/June 2025 MARITIME Electric ferry targets 2026 Incat in Australia is constructing a 78 m hybrid electric ferry that will be ready for operation in the first half of 2026, writes Nick Flaherty. The 78 m craft, as yet unnamed, has flexible propulsion options with a fully electric battery system of up to 12 MWh as well as hybrid and generator-assisted options. The system supports charging at rates up to 10 MW to reduce the turnaround time. The vessel can carry 600 passengers and the 12 MWh pack gives it a top speed of 27 knots. Additionally, two 230 kW bow thrusters provide enhanced manoeuvrability. The design incorporates lessons learned from the world’s largest batteryelectric ship, the 130 m Hull 096, aimed at cruise ship operations and set to launch on May 1, 2025. Hull 096 uses an electrical system developed by Wärtsilä and the Dolphin NextGen battery system from Corvus Energy that is expected to be used for this smaller version. The battery system for Hull 096, based on the Corvus Blue Whale architecture, incorporates lithium-ironphosphate (LFP) batteries with mechanical and electrical design specifications of a 48.23 kWh, 80 V DC module with capacity of 628 Ah. This provides a pack size ranging from 336 kWh at 560 V to 5.4 MWh at 1120 V with forced air cooling. However, the Dolphin power variant likely to be used for the electric ferry uses lithium NCA (nickel-cobaltaluminium oxide) cells for faster charging in a 6.56 kWh, 50 V module that holds 152 Ah. This would lead to a battery system with over 1800 modules that weighs 86 tonnes. A sister ship in the pipeline could be available within 12 months. The 78 m electric ferry (Image courtesy of Incat) Digital twin for material optimisation battery manufacturers to optimise designs at the earliest development stages, by simulating and testing the battery systems virtually before physical prototyping. Henkel offers four key types of battery simulation for structural integrity, thermal management, fire safety and material application. Structural simulation evaluates battery pack durability and crash resistance, Predictions of heat flow through different mechanisms and pathways help design a safer battery system (Image courtesy of Henkel) optimising designs for weight reduction, robustness and performance under mechanical loads such as impact, crushing and vibration. A thermal management simulation models the heat dissipation and cooling efficiency to analyse the battery performance, lifespan and fast-charging safety in extreme operating conditions. Thermal event simulation predicts heat propagation pathways during a thermal runaway event to enhance battery safety measures and material utilisation, thereby reducing risks for passengers and critical components. The material application simulation models the application of adhesives and sealants used in EV battery production. This reduces risks such as void formation, excessive squeeze-out and component stress. This end-to-end digital twin modelling capability complements Henkel’s Battery Test Centre in Düsseldorf, Germany, which hosts the material and battery testing that provides the underlying data for the digital twin models. Henkel is launching digital twin modelling and simulation capabilities combined with real-world validation of structural materials used in e-mobility designs, writes Nick Flaherty. Henkel is combining its expertise in material application with in-house testing and validation to close the loop between digital and real-world design and testing. “Henkel’s simulation can optimise electric vehicle (EV) battery designs with greater speed, accuracy and efficiency,” says Dr. Stefan Kreiling, global head of innovation for automotive components at Henkel. “By integrating material simulation with real-world validation, we help accelerate innovation cycles, reduce development costs and bring safer, high-performance battery systems to market faster.” The digital twin technology provides a closed-loop battery and materials development process using models of the battery systems and the adhesives, thermal interface materials and battery safety coatings. This allows OEMs and
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