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ANSYS model simulations of battery pack enclosure representing its deformation analysis (maximum deformation of 0.00063349 m)
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Vibrations shocks induced during working conditions cause stresses and deformations of the battery case parts and heating may cause fire, which affects vehicle safety. Hence, the battery case and its parts should be of better mechanical features and lightweight to make the vehicle more efficient and safer. To achieve all the requirements, cold spra...
Citations
... A stand-alone polymer composite without any reinforcements is relatively rare in vehicle technology since its mechanical strength and structural integrity are its main assets. The design and optimization of composite carbon fiber battery box structures require careful consideration of various factors [18,19]. Load requirements, such as mechanical forces and vibrations experienced during vehicle operation, must be addressed to ensure structural integrity and safety. ...
The use of a polymer composite material in electric vehicles (EVs) has been extensively investigated, especially as a substitute for steel. The key objective of this manuscript is to provide an overview of the existing and emerging technologies related to the application of such a composite, especially for battery pack applications, in which its high strength-to-weight ratio, corrosion resistance, design flexibility, and durability are advantageous compared to any metal in general. This study explores the key considerations in the design and fabrication of composites, including base material selection, structural design optimization, reinforcement material, manufacturing processes, and integration with battery systems. The paper also discusses the performance characteristics of composite battery pack structures, such as mechanical properties, thermal management, safety aspects, and environmental sustainability. This study aims to contribute to sharpening the direction of future research and innovations in the area of composite battery pack technology.
... Zhu et al. [9] suggested structural design changes to make batteries safer against ground impact. Pal et al. [11] suggested the use of cold-spraying technology for additively manufacturing battery enclosures. Shui et al. [12] developed a four-phase design optimization methodology to optimize the features of the mechanical design of the enclosure of the battery pack. ...
This work investigates the crashworthiness of carbon fiber ply-based electric vehicle’s (EV) battery enclosure, which is a large component currently made using aluminum alloys. A finite element analysis based framework was used to perform the thermoforming simulation followed by as-formed structural analysis to examine the strength of carbon fiber plies in the structural design of an EV battery enclosure. Simulations were performed for the thermoforming process of the enclosure panel and side pole impact test of the as-formed part. In step one, using a thermoforming simulation, carbon fiber layers were formed on the surface of a die representing the geometry of the desired battery enclosure. In step two, a side pole impact test was simulated to investigate the crashworthiness of the battery enclosure for various impact speeds. Different crashworthiness characteristic parameters such as peak load, average load, crush load efficiency, energy absorbed, material damage, and material deformation were calculated from the results. The effect of impact speed and the number of carbon fiber layers on all the crashworthiness characteristic parameters were studied in detail. The behavior of the enclosure obtained by the crash test was compared with the behavior of an enclosure made from traditional aluminum alloys and the crashworthiness of both materials was found to be similar for a wide range of impact speeds. An isotropic elasto-plastic material model along with FLD (Forming Limit Diagram) damage model was used for aluminum alloy material.
... Liquid-cooled BTMS using cooling channels and aluminum conduction element [211]. [223]. The design factors impacting the safety and dependability of the EV battery pack were also examined by taking into account a battery pack with 132 prismatic-type cells arranged into 6 rows of 22 cells, and the battery pack assembly made of 4 mm thick stainless-steel plates [224]. ...
... Pal et al. [223] Cold-sprayed aluminum 4. ...
... The excellent mechanical properties of the battery pack provide a more prominent degree of security and enhance the safety of EVs. The battery pack enclosure, as a vital boundary to maintaining the structural reliability of the battery pack, has gotten more consideration from EV producers [5] and lots of studies have done on efficient and lightweight design of battery pack enclosure by researcher worldwide. ...
... The objectives of optimization were minimizing deformation, maximization of frequency to avoid resonance conditions, and minimization of battery pack enclosure mass. The optimization results for cold sprayed aluminum material were compared with the results obtained using bulk aluminum [5]. Wang et al. used Pareto solutions for multi-objective topology optimization to optimize the design of the traction battery enclosure. ...
... 4. Most of EV's battery thermal management study had done with a natural cooling mechanism which was less effective for temperature distribution which causes failure of battery performance, so needs to study more effective ways of the cooling mechanism of battery to improve life [38]. 5 ...
An electric vehicle battery pack which is a gathering of battery modules which subsequently comprised of the battery cell is a primary source of control transmission for an Electric Vehicle (EV). The inappropriate design of the battery enclosure will cause many genuine issues, such as cracking, causing noise, or battery harm. At the same time, the weight of the battery enclosure is huge; in order to get better the driving range of the electric vehicle and diminish the influence of the battery on the vehicle dynamic performance and acceleration performance, it is essential to carry out the lightweight design of the battery enclosure. This paper reviews the multi-material battery enclosure design optimization, the multi- technologies, and a proficient Battery Management System (BMS) for compact battery pack design used to lightweight battery pack enclosure design; the multi-objective optimization approach for distinctive parameters of battery pack enclosure design optimization by diverse manufacturing techniques.
This paper presents a comprehensive survey of optimization developments in various aspects of electric vehicles (EVs). The survey covers optimization of the battery, including thermal, electrical, and mechanical aspects. The use of advanced techniques such as generative design or origami-inspired topological design enables by additive manufacturing is discussed, along with sensitivity studies of battery performance with alternate materials and incorporating sustainability considerations. Strategies for battery charging/discharging and battery swapping are reviewed, taking into consideration factors such as operation, cost, battery performance, and range anxiety. Future research is suggested to address uncertainties in charging ecosystem design and incorporate both forward and inverse prediction capabilities, leveraging benefits for both the grid and individual vehicles. The optimization techniques for other EV components, such as motors, powertrains, tires, and chassis, are also discussed. Finally, this paper presents a review of the EV management, specifically the optimization of charging station, grid, and fleet management, including research on charging station construction, charging station operation strategies, and power system operation strategies. The need for further research on robustness, reliability, and sustainability is emphasized to justify the use of EVs in the future.
Recently, Electric Two-Wheelers ETW are changing the face of the global automotive market. This study focused on selecting proper material and mechanical isolation gap to design a protective enclosure for the battery pack of ETW. The integration of the Failure, Modes, Mechanism and Effect Analysis (FMMEA) method is utilized to develop the interface matrix and the severity index of different components of the enclosure. By analyzing different forces from the road conditions, dynamics during turn, acceleration, and deceleration with the enclosure, it becomes a crucial load-bearing element. Employing Finite Element Modeling (FEM), structural strength using materials like AL6061, Q235, C22000, DC 01 and Teflon are assessed under varying static, dynamic and thermal conditions. Modal analysis is conducted to observe the excitation frequencies where the maximum deformation for the metal enclosure is observed beyond 500Hz. AL6061 material that can withstand the stresses and deformations that are under allowable stress limits with negligible deformation is most preferable material based on the results. Minimal of 2.5 mm gap to be provided in case of metal casing and 10mm in case of Teflon is proven.
Cellular structures can be classified into foams, honeycombs, and lattice structures. Each type of structure has its characteristics. Various applications of cellular structures can be found in aviation, bioengineering, automotive, and other fields. In the automotive sector, cellular structures have been used for structural applications and impact- absorbing modules, for example, for protecting the electric vehicle battery pack against impact loading. The challenges that limit the application of cellular structures today include systematically designing pseudo-random cellular structures, assessing which cellular patterns are most suitable for a particular application, and mastery of manufacturing technology for efficient mass production of cellular structures. In this paper, the authors examine the state-of-the-art technology in geometry, applications, and manufacturing of various cellular structures carried out by researchers to obtain an overview of the current conditions for further development of these cellular structures. Limited manufacturing capabilities encourage researchers to design an optimal cellular structure to be applied to a particular function but have high manufacturability. The development of additive manufacturing technology has provided opportunities for researchers to produce an optimal cellular structure commercially soon.
A battery tray for electric vehicles is fundamentally a multi-objective design optimization problem. Obtaining trade-off solutions between conflicting functional objectives can be computationally expensive when high-fidelity dynamic Finite Element Analysis (FEA) simulations are used for performance evaluations. Sometimes it is even difficult to obtain any feasible solution. In this work, battery tray design exploration is performed using data-driven surrogates and multi-objective genetic algorithm (MOGA) to obtain the best structural performances while keeping the cost low. Finally, a design is accepted that is slightly heavy than the baseline design but beats the market in cost while meeting all other functional requirements.KeywordsElectric vehicleBattery trayMulti-objective optimizationSurrogate modelingKriging
