Safety Modeling of High Voltage Cabling in Electrified Powertrains

Paper #:
  • 2017-01-0361

Published:
  • 2017-03-28
Abstract:
Modeling of high voltage (HV) wires is an important aspect of vehicle safety simulations of electrified powertrains, in order to understand the potential tearing of the wire sheath or pinching of high voltage wiring. The behavior of these wires needs to be reviewed in safety simulations to identify potential hazards associated with a high voltage wire being exposed, severed or coming in contact with ground planes during a crash event. Modeling high voltage wire is challenging due to the complexity of the physical composition of the wire, which is usually comprised of multiple strands bundled and often twisted together to form the high voltage electrical conductor. This is further complicated by the existence of external insulating sheathing materials to prevent high voltage exposure during normal operating conditions. This paper describes a proposed method to model and characterize different types of high voltage wires for usage in component and vehicle level safety models. The resulting approach enables the CAE analyst to visualize the 3D behavior of the wire during a crash event simulation. It also provides the steps needed to validate the model via simplified physical lab testing of wire samples. An example of how to apply these models to a generic high voltage battery design is also provided.
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