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2015 Vibration Fatigue Analysis of

Battery Pack

Dassault Systemes Korea

Jeon, Hojin

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Introduction

Steady state dynamic analysis using Abaqus

PSD Fatigue analysis using fe-safe

Bead optimization using Tosca

Summary

Contents

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2015 Introduction

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Thermal Performance Crush

Battery Cell Level Battery Module Level Battery Pack Level Full Car Level

Battery Simulation for Electric Vehicle

External Impact NVHImage ref. : www.gm.com

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Random Vibration Test for Battery Pack

Image ref. : www.rsp.coo.kr

X-direction

Y-direction

Z-direction

Frequency [Hz]

PSD

[G

2/H

z]

Shaker test bench Test condition(ISO12405-3)

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Vibration fatigue analysis using PSD

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Simulation Workflow

5

3

1

Frequency analysis SSD analysis

Fatigue analysis from PSD

Bead optimization

Abaqus fe-safe

Tosca

2

Frequency analysis Steady state dynamic

analysis

Fatigue analysis from PSD

Abaqus fe-safe

4

Optimization

analysis

Initial analysisDesign

Optimization

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2015 Steady state dynamic analysis

using Abaqus

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Battery pack assembly

Battery Cell(pouch Type)

Battery Module Battery Pack Electric Car

Image ref. : www.gm.com

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Simulation model

Battery ModuleBattery Cell(size 170 x 200 x 60 mm)

Battery Module(size : 270 x 250 x 210 mm)

Battery Pack

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Materials

Part Name Material

1 Battery Cell Equivalent Material

3 Battery Module Bottom Plate Steel

4 Battery Module Frame Glass Fiber 30%

5 Battery Module Front Cover Steel

6 Battery Module Top Cover Steel

7 Battery Module Upper Plate Steel

8 Battery Pack Bottom Cover Steel

9 Battery Pack Top Cover Steel

10 Battery Module Cooling Plate Aluminum

11 Bolt Steel

12 Shaft Steel

Battery Module Cover

Battery Module Front Cover

Battery Module Plate

Battery Module Frame

Bolt

Battery CELL

Battery Module Bottom Plate

Shaft

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Frequency analysis

Boundary condition

Fixed holes for mounting

Top view

Mode Frequency (Hz)

1 38.446

2 42.448

3 53.599

4 119.04

5 158.32

6 173.33

7 181.10

Results

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Frequency analysis

1st mode (38.446 Hz) 2nd mode (42.448 Hz) 3rd mode (58.599 Hz)

Battery Pack

Bottom Cover

Results

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015 Results

Steady state dynamic analysis

3rd mode(58.59Hz)71MPa

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2015 PSD fatigue analysis

using fe-safe

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Methodology for vibration fatigue from PSD

Abaqus

fe-safe

User Input

Frequency

Analysis

Mode-based

SSD with Unit

Response

Frequency

Response

Function

PSD Matrix

From Standard

von Mises

PSD

Calculation of

Rainflow rangeLIFE

DAMAGE

Abaqus fe-safe

SN curve

Sherrat-Dirlik method

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Fatigue analysis from PSDResults

71MPaFatigue life:

185回

Steady state dynamic Fatigue analysis

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2015 Bead optimization using Tosca

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Effect of Bead

Deflection of Beam without Bead : 100%

Deflection of Beam with Bead : 10%

Initial State without Bead Design Optimization with bead

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Tosca/structure in Abaqus/CAE

Optimization Task

Design Response

Objective Function

Constraint

Tosca/structure in Abaqus/CAE Bead optimization

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Bead Optimization

Optimization region

Bottom plate of battery pack

Design response and Objective function

• Design response: natural frequency of mode 3

• Objective function: Maximize design response

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Bead Optimization

53.94Hz 58.75Hz 78.55Hz 100.96Hz53.59Hz

initial 1st iteration 2nd iteration 3rd iteration 4th iteration

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Bead Optimization

Initial design Optimization design

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Bead Optimization

Fatigue life:

21,350回Fatigue life:

185回

Initial design Optimization design

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2015 Summary

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Summary

The workflow for vibration fatigue analysis using PSD was introduced.

Fatigue life was predicted by using PSD input and fe-safe after frequency analysis and steady-state

dynamic in Abaqus.

Bead optimization in Tosca was used to improve the design of the predicted failure at the initial

design stage.

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2015