Numerical Modeling and Safety Design for Lithium-Ion Vehicle Battery Modules Subject to Crush Loading

Feng Zhu, Runzhou Zhou and David J. Sypeck
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Feng Zhu: Hopkins Extreme Materials Institute (HEMI), Johns Hopkins University, 3400 N. Charles Street, Baltimore, MD 21218, USA
Runzhou Zhou: Hopkins Extreme Materials Institute (HEMI), Johns Hopkins University, 3400 N. Charles Street, Baltimore, MD 21218, USA
David J. Sypeck: Department of Aerospace Engineering, Embry-Riddle Aeronautical University, 1 Aerospace Blvd, Daytona Beach, FL 32114, USA

Energies, 2020, vol. 14, issue 1, 1-24

Abstract: In this work, a computational study was carried out to simulate crushing tests on lithium-ion vehicle battery modules. The tests were performed on commercial battery modules subject to wedge cutting at low speeds. Based on loading and boundary conditions in the tests, finite element (FE) models were developed using explicit FEA code LS-DYNA. The model predictions demonstrated a good agreement in terms of structural failure modes and force–displacement responses at both cell and module levels. The model was extended to study additional loading conditions such as indentation by a cylinder and a rectangular block. The effect of other module components such as the cover and cooling plates was analyzed, and the results have the potential for improving battery module safety design. Based on the detailed FE model, to reduce its computational cost, a simplified model was developed by representing the battery module with a homogeneous material law. Then, all three scenarios were simulated, and the results show that this simplified model can reasonably predict the short circuit initiation of the battery module.

Keywords: Li-ion battery module; crush loading; failure models; structural response; energy absorption; finite element analysis (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2020
References: View references in EconPapers View complete reference list from CitEc
Citations: View citations in EconPapers (1)

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