CAE Method for Evaluating Mechanical Performance of Battery Packs under Mechanical Shock Testing

Paper #:
  • 2017-01-1193

Published:
  • 2017-03-28
Abstract:
The United Nations regulation for Lithium metal and lithium ion batteries section 38.3-T4 rev. 5 shock test requires that each cell or battery pack be subjected to 3 shocks in the positive direction followed by three shocks in the negative direction, of three mutually perpendicular mounting positions. This paper focuses on the no-disassembly requirement of UN 38.3-T4 under those testing conditions and on the CAE methodology specifically developed to perform this assessment. During the design phase of Ford’s current generation of air-cooled, prismatic cell lithium-ion Plug-in Hybrid Electric Vehicles (PHEVs), a CAE analysis method was developed to simulate this test and to assess the possibility of cell dislodging. This CAE method helped identify and diagnose the potential failure modes which helped the design team by developing a strategy to meet the required performance under UN38.3-T4 test loads. The final CAE-driven design focused on the structural requirement and optimization, and lead to cost saving without compromising cell performance, Physical testing performed on the final optimized design correlated with CAE results thus providing validity to the simulation methodology.
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