Opening Report IBNA Kawsar
Opening Report IBNA Kawsar
Opening Report IBNA Kawsar
研究生学位论文选题报告
学 号: L2200089
姓 名: Ibna Kawsar
导 师: 潘勇军
专 业: 机械
.
研究方向: 电池包系统动力学与机械安全
填写时间: 2023 年 12 月 27 日
重庆大学机械与运载工程学院制
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论文题目: Enhancements in crashworthiness through structural innovation of CTC
battery packs.
论文类型 2)应用基础研究
Type of Thesis: (2) Applied Basic Research;
课题来源:(1)纵向课题
Source of Topic: (1) Vertical Project;
The demand for efficient and sustainable energy storage systems has experienced
significant growth in recent years. This growth can be attributed to the rapid increase of
electric vehicles (EVs), renewable energy sources, and portable electronic gadgets.
Lithium-ion batteries (LIBs) have gained significant attention as a highly favorable
energy storage technology owing to their exceptional attributes, including remarkable
energy density, extended cycle life, and minimal self-discharge rate. With the rapid
development of China's automobile industry, electric vehicles rank first in the world. As
a key core component of electric vehicles, the battery pack system plays a vital role in
power supply.
effective protection against external hazards and reduce the impact of the battery pack
system on electric vehicles.[3]–[5].
Research has been conducted by relevant companies and universities in recent years
to determine whether different materials and thickness parameters of battery pack system
components can reduce collisions. Wisch et al. and other researchers have conducted a
number of critical crash tests as part of the EVERSAFE safety project, which
encompasses frontal, side, and rear crash scenarios[6], [7]. Xiong et al.[8] determined that
the maximal crash stress occurred between the X-axis (frontal impact) and Y-axis (lateral
impact), with the X-axis experiencing a higher stress of 18.71 MPa than 16.45 MPa on
the Y-axis is showed in fig 2. In the same way, Pan et al.[9] conducted crash analyses on
the BPE and found that X-axis stresses were greater than Y-axis stresses. Additionally,
the crush test has also been considered a significant safety test. The battery is protected
against crushing forces by structural reinforcements, rigid materials, and crash-resistant
compartments[10]. According to Pan et al.[11] the enclosure deformed 81.68 mm when
it was crushed with a standard force of 100 kN. The deformation of the battery was within
the acceptable limit. Therefore, the battery was considered safe for the intended use.
BP X axis crash
BPE X axis crash
Original
BPS
In crushing simulations, the best BP designs were verified based on the validated test
standard and FE BP model. Several comparable accident incidents were illustrated using
the Volvo C30 (1GEV) and Toyota Yaris (ICE). At 56 km/h, the frontal collision between
the C30 and Yaris was equivalent to the Euro NCAP frontal ODB test at 64 km/h. The
pillar collapsed due to the smaller passenger cabin of the Yaris[12].
Several patents have been filed to prevent severe accidents and create a safe zone in
the passenger cabin using a novel design model theory. A novel CTC battery pack,
developed by Cheng et al. [13] features a reinforced structure, lightweight components,
and improved structural strength and safety. CTC battery pack is connected with the front
vehicle bridge section and the rear vehicle bridge section through fasteners of the vehicle
frame connecting section to form a middle beam type sliding plate chassis[14].
An average conventional battery pack (CTP) consists of four parts: the bottom case,
the top cover, the battery module, longitudinal beams, cross beams, mounting plates,
lifting lugs, and brackets. The CTP battery pack is composed of individual cells arranged
into modules and then integrated into a pack. This causes a severe deflection in a crash.
The installation and packaging systems of these battery pack devices are not highly
reliable. To deal with these issues, companies and institutions have initiated research on
novel cell-to-chassis (CTC) structural battery pack systems. To address several
challenges, such as implementing CTC battery systems, reducing maintenance costs, and
achieving a lighter battery by directly installing it on the chassis. In this situation, the
chassis structure would serve as a savior by capturing and utilizing the kinetic energy
during collision. This ideal structure exhibits reduced crushing stress and increased
fatigue life when subjected to crushing circumstances.
In order to design a battery pack system, the goal is to conduct appropriate safety
evaluations and create designs that minimize deformation after collisions. In addition,
research and development should focus on analyzing the fracturing activity of individual
batteries’ interior and exterior frame components. Enhancing our insight into the battery
system's behavior during collisions would facilitate the development of strategies to
mitigate BP damage in accident scenarios.
A car safety system has been implemented to mitigate crashes and absorb impact
energy through a crush-resistant frame[15][16]. The implementation of a structural bio
inspired crush box in the battery pack system can enhance the design of the developing
structure. Shuai et al. designed and optimized a new thin-walled honeycomb structure for
Li-ion battery packaging to protect the internal battery and improve the safety of an
electric vehicle[17]. Hao et al. indicated that using an energy- absorbing structure of
battery module has the potential to overcome the limitations in battery-powered electric
vehicles[18].
A number of patent innovations are integrated into the design of CTC battery packs
in order to optimize structural development, resulting in a lightweight and dependable
system that also facilitates the evaluation of the installation process. In addition, a more
robust and secure design is needed to enhance mechanical safety, including protection
against crashes, crushing, and other safety-related incidents. This involves examining the
battery system’s behavior during a crushing event, analyzing the influence of the battery
system’s design on the structure’s behavior, and developing novel designs that protect the
BP during crash and crush events. Patent CN115891607A[19] outlines a CTC battery
pack for a sliding plate chassis, comprising a fastener, upper box cover, sealing strip,
frame, battery module, and lower box body. Moreover, CN116759729A[20] forms a
three-section skateboard chassis, allowing for easy removal and replacement. This
versatile structure is suitable for various vehicle types with the same wheelbase, allowing
for flexibility in battery pack extension or shortening.
Theoretically, the integration of CTC battery packs into vehicles has the potential to
enhance structural integrity through the optimization of impact energy dispersion during
collisions. This has the potential to result in decreased harm and enhanced security[19].
An equal distribution of impact forces can enhance crashworthiness by preventing
localized damage. Strategically positioning energy storage within the chassis can
optimize the distribution of weight, enhance stability, minimize the likelihood of
rollovers, and improve handling by lowering the center of gravity[21]. In addition, the
incorporation of batteries can have a favorable effect on vehicle dynamics, improving
handling, performance, and overall efficiency, thus enhancing the driving experience.
This battery packs represent an innovative strategy for enhancing crash safety by
prioritizing the structural strength and efficient distribution of energy[20], [22], [23].
A bio-inspired crash shield combined with the CTC battery pack offers the
automotive industry an edge in terms of technological innovation, giving companies
an advantage over competitors. In theory, crash boxes provide efficient safety
features, while in practice they provide safety, weight reductions, sustainability, and
compliance with regulations.
1.3 The Current Status of Research and Development at Home and Abroad
Fig 3. The battery pack system in frontal and side crashes and its behavior.
As a quantitative framework for assessing optimization plans' efficacy, Chen et
al.[28] developed a specialized crush effect in collaboration with other researchers. It
provides a crucial metric for assessing structural enhancements since it establishes a
relationship between the maximum crush force and the additional weight. Contributions
by Pan et al. have been highly significant because they provide valuable insights into
deformation analyses conducted during crush tests. There have been promising results
from these analyses with models that have reduced thickness and increased resistance to
deformation. Patents such as CN108417745B[29] illustrate innovative solutions in the
area of battery protection. These developments strengthen the overall structure of the
vehicle by increasing the stiffness of battery holder containers. To achieve comprehensive
collision safety, the dual-benefit approach, which enhances battery protection while
simultaneously reducing weight and material requirements, represents an important
development.
Crash-resistant Battery Protection (BP) devices are crucial for maintaining the safety
of electric vehicles (EVs) in the event of collisions. An all-encompassing strategy entails
integrating mechanical characteristics into the design in order to improve reliability and
security. The deployment of crash prevention systems is of utmost importance, with the
objective of withstanding impact forces and minimizing the probability of damage,
rupture, or thermal runaway. The process of designing the BP and its external shell is a
careful and detailed one, with the primary goal of reducing the dangers connected with
internal short circuits. These short circuits have the potential to have severe consequences
in the case of a crash.
Diverse safety precautions are utilized, such as fortified enclosures, materials that
absorb impact, and separators. The primary objective is to ensure the protection of the
battery and mitigate the risk of severe malfunctions that may lead to combustion or
explosion[38]. Electric vehicle (EV) battery packs employ many packing formats,
including "T-shaped" and "floor" arrangements. The T-shaped design strategically
positions battery modules within the vehicle's primary protection area, prioritizing the
safeguarding of the battery pack (BP) from frontal and side accidents at the expense of
interior room and passenger comfort[39]. On the other hand, the floor layout optimizes
the amount of space inside the cabin, but also leaves the BP vulnerable to potential
damage from contact with the ground or other surfaces below. Although safety has
improved, the majority of current electric vehicle (EV) designs place the battery pack
(BP) outside of the primary safety zone or passenger compartment[2]. Nevertheless, [40]
have suggested a novel method that involves incorporating an additional safety zone
battery. This battery would be installed in the front compartment of the car, specifically
in front of the firewall. The introduction of multifunctional Granular Battery Assembly
(GBA) packs has shown substantial progress in reducing the likelihood of electric vehicle
(EV) damage. Research indicates that the efficacy of mitigating blood pressure failure in
collision scenarios is significantly greater when using advanced non-metallic foam
structures as opposed to conventional metallic foam structures[40][41]. Researchers, such
as Wisch et al.[42] provide essential knowledge by conducting rigorous crash tests that
examine several types of collisions, including frontal, side, and rear impacts. The frontal
pole collision, which is regarded as the most severe, is thoroughly examined to
comprehend its effects on both the electric vehicle (EV) and its battery pack (BP).
Significant progress in crash protection systems is seen in patents like JP Patent No.
6303030B2[43] and JP Patent 2021011222A[44] which present novel designs for
protecting the rear section of the battery. These designs not only increase the ability to
absorb impact energy, but also establish areas of protection to safeguard the battery from
external forces, thus enhancing safety. Crush protection is a crucial factor that deals with
the potential for the BP to be compressed by external pressures that are not related to a
collision. Structural reinforcements, inflexible materials, and crash-resistant chambers are
utilized to safeguard the battery from compressive stresses. Optimal BP designs are
evaluated by conducting crushing simulations, with a focus on minimizing crushing stress
and enhancing fatigue life under crushing conditions. US Patent No. 20220410973A1[45]
outlines detailed designs for protective measures in the event of crash, which involve the
incorporation of side seal reinforcing elements. These members serve the purpose of
absorbing force energy and safeguarding the battery case from potential damage.
The majority of research conducted in the past decade has focused on the safety of
traditional battery packs and their susceptibility to significant deformation during crash
crush events. Several patents have been disclosed that solely address the design technique
of the CTC battery pack system, without discussing its safety behavior or providing
guidance on how to ensure the safety of the battery pack in crash or crush events. We
have developed an innovative configuration for a CTC battery pack system in our
research. We will explain the collision effect and demonstrate the superiority of our
innovative construction compared to the conventional structure.
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This overview will provide a thorough explanation of the CTC battery pack design,
encompassing its structural components, essential elements, and pioneering
characteristics. Notably, the design incorporates with six individual bio-inspired multi-
cell square tubes structure for the side crush shield, which enhances side crash
performance and effectively absorbs crush energy, resulting in improved crashworthiness
as well as.
A FEM analysis of the CTC Battery pack CAD model must be performed, followed
by crashworthiness testing according to crash testing standards. Using this information,
battery packs can be designed to be more efficient and effective by analyzing their energy
absorption, maximum stress, and deformation. Further, it allows for the identification of
possible failure sources and more precise safety testing.
Create six separate side crash shields using six distinct varieties of bio-inspired
square tubes. To mitigate the potential consequences of collisions, ensure that each
multiple-cell tube can absorb impact energy. In addition, to choose better energy
absorbers to prevent battery pack deformation, robust safety measures must be
implemented.
Finally, perform a thorough examination to compare the CTC battery pack with
traditional designs, emphasizing the benefits and possible enhancements in crash
performance.
• Conducts side crush test on primary structure of CTC battery pack system.
• Identifies deformation after test and uses Simplified Super Folding Element (SSFE)
theory for the design of the side crash shield.
𝑑
𝐸𝐴(𝑑) = ∫ 𝐹(𝑥)𝑑𝑥
0
where d represents the effective crushing displacement and F(x) represents the axial
crushing force. Conversely, the calculation of Pm for a specified compression
displacement d is as follows:
𝐸𝐴(𝑑)
𝑃𝑚 =
𝑑
SEA is the ratio of the energy absorption to the mass of the columns, and it is used
to evaluate the energy absorption of energy absorbers. An energy absorber of greater SEA
is desirable.
𝐸𝐴(𝑑)
𝑆𝐸𝐴 =
𝑚
The experimental plan for the cell-to-chassis battery pack system side crash test
involves a comprehensive assessment of the system's crashworthiness and safety
performance. Selecting representative crash scenarios, defining impact parameters, and
identifying key performance metrics are the first steps in the analysis. To determine if the
battery pack is structurally sound, to evaluate energy absorption mechanisms, and to
evaluate whether the chassis may be damaged during the feasibility analysis. For
validation of theoretical models and real-world applicability, rigorous testing will be
conducted using advanced simulation tools and physical crash tests. To assess
compliance, regulatory standards, and industry benchmarks will be considered. The
feasibility of a project will be determined by balancing optimal safety requirements with
practical implementation considerations such as cost-effectiveness and manufacturability.
It is intended to provide valuable insight into the system's crash response, which will
assist in the development of design enhancements and ensure the overall viability of the
cell-to-chassis battery pack configuration in side impact scenarios.
3 Research Plan and Expected Progress (研究计划及预期进展)
Time Research Content Expected Outcomes
(时间) (研究内容) (预期效果)
2023-12-27 to Developing FEM knowledge and Accurate optimization of meshing
2024-03-31 improving the structure of the battery performance and determination of
pack system the ideal thickness parameter for
improved structural performance.
2024-07-21 to Develop parametric designs for each of Design parametric designs and
2024-10-31 the six types of side crash shields. optimize the thickness of bio-
inspired multi-cell tubes for the
side crash shield, and select the
optimal energy absorber to
mitigate the deformation of the
battery pack after a crush test.
⎯ Cell to Chassis CTC battery scheme shows highest space utilization rate, improving battery
⎯ The CTC battery pack side crash shield produces the highest energy absorption and delivers the
⎯ A literature review has already been completed and submitted to a journal, which is
currently reviewing it. Safety standards are discussed in this paper, research findings
are presented, and patentable concepts are discussed for batteries for electric
vehicles. In addition, guidelines for electric vehicle safety are provided when they
are subjected to extreme vibrations, shocks, and collisions. The design stage of our
cell to chassis battery pack research has also been completed.
⎯ We plan to conduct a side crash analysis of the CTC battery pack system safety
based on our completed research concept. The battery damage should be assessed
according to mechanical standards, however. It is also a completely novel structure,
combining bionic multi-cell structures for the development of an energy-absorbing
side crush system. To determine the solution to the safety test, we need to study
more literature.
⎯ This work was supported by the Research Project of the“State Key Laboratory
签名:
日期: 年 月 日
8 Documentation of selected subjects (选题报告会记录)
(着重记录评审专家的质疑问题与研究生的回答要点,以及专家对选题的具体修
改意见)
1. How do you going to do your simulation part for the battery pack system?
Answer: I am going to use hyper mesh and ls dyna for the crash test of the battery
pack system.
2. What is your innovation for your research?
Answer: The majority of battery pack systems in my research utilize the Cell to
Pack battery system. However, for my study, I have opted for the Cell to Chassis
battery pack system, which is a novel approach in the research field. Furthermore,
I have developed a crash shield for side crashworthiness, which can be
conveniently installed in a battery pack without the need for additional lifting
equipment.
3. Did you finish any part of the thesis?
Answer: Yes, I have completed the design of CTC battery pack and doing
additional correction for the design.
4. Do you have any plan to experiment the crash analysis?
Answer: Although I do have a plan, conducting accident tests is difficult due to
their exorbitant cost. Nevertheless, prior research exists to corroborate my design
analysis. My accident test data will be compared to that of previously published
research.
5. What is the connection between the battery pack and the bio-inspired shield you
have selected? What is the objective of employing this bio-inspired shield?
Answer: I have selected a bio-inspired shield due to its lightweight nature and its
ability to efficiently absorb crash energy. I will be utilizing six distinct types of
multi-cell tube structures and conducting an analysis on each of them.
Subsequently, I will use the most effective absorption structure as a side crash
shield for the battery pack.
9 Results of evaluation of thesis selection (论文选题评价结果)
(请评审专家在相应等级后的“( )”内打“√”,并给出评语)
评语:
评审专家小组签名:组长
成员
时间: 年 月 日