IDEAS home Printed from https://ideas.repec.org/a/eee/appene/v357y2024ics0306261923018457.html
   My bibliography  Save this article

Deep learning-based vibration stress and fatigue-life prediction of a battery-pack system

Author

Listed:
  • Zhang, Xiaoxi
  • Pan, Yongjun
  • Xiong, Yue
  • Zhang, Yongzhi
  • Tang, Mao
  • Dai, Wei
  • Liu, Binghe
  • Hou, Liang

Abstract

The primary concerns of the automotive industry are structural integrity and battery-pack system (BPS) reliability. To ascertain the appropriate thickness of critical BPS components (e.g., the long bracket, crossbeam, and bottom shell), engineers are required to perform several simulations of finite element (FE) analysis. This procedure is laborious and requires a significant amount of time. This study introduces a very effective approach for predicting vibration-induced stress and fatigue life, intending to enhance dependability in the design process. Firstly, a three-layer lithium battery model is utilized to investigate the impact of vibration on the maximal Mises stress at various states of charge. This information is used to model the BPS, including the batteries. The nonlinear FE model of the BPS is validated using the modal test results. Secondly, a sensitivity analysis is performed to ascertain the impact of component thickness on the maximum Mises stress. For vibration simulations, multiple design variables are selected to collect data. Next, the nonlinear relationship between inputs (thicknesses of critical components) and outputs (maximum Mises stress and minimum fatigue life) is described using a deep learning (DL) modeling framework with forward and backward propagation. Finally, the accuracy of the DL model is assessed by measuring error functions and comparing its performance to six commonly employed methods. Furthermore, the inclusion of Gaussian noise is employed to assess the model’s robustness and ability to generalize. Additionally, the establishment of fatigue-life and stress boundaries serves to offer designers valuable insights. The results indicate that the proposed method for predicting vibration stress and fatigue life is highly efficient and cost-effective, making it useful for the design of a robust and reliable BPS.

Suggested Citation

  • Zhang, Xiaoxi & Pan, Yongjun & Xiong, Yue & Zhang, Yongzhi & Tang, Mao & Dai, Wei & Liu, Binghe & Hou, Liang, 2024. "Deep learning-based vibration stress and fatigue-life prediction of a battery-pack system," Applied Energy, Elsevier, vol. 357(C).
    • Handle: RePEc:eee:appene:v:357:y:2024:i:c:s0306261923018457
    DOI: 10.1016/j.apenergy.2023.122481
    as

    Download full text from publisher

    File URL: http://www.sciencedirect.com/science/article/pii/S0306261923018457
    Download Restriction: Full text for ScienceDirect subscribers only
    File URL: https://libkey.io/10.1016/j.apenergy.2023.122481?utm_source=ideas
    LibKey link: if access is restricted and if your library uses this service, LibKey will redirect you to where you can use your library subscription to access this item
    ---><---

    As the access to this document is restricted, you may want to

    for a different version of it.

    References listed on IDEAS

    as
    1. Jie Deng & Chulheung Bae & James Marcicki & Alvaro Masias & Theodore Miller, 2018. "Safety modelling and testing of lithium-ion batteries in electrified vehicles," Nature Energy, Nature, vol. 3(4), pages 261-266, April.
    2. Li, Shuangqi & He, Hongwen & Li, Jianwei, 2019. "Big data driven lithium-ion battery modeling method based on SDAE-ELM algorithm and data pre-processing technology," Applied Energy, Elsevier, vol. 242(C), pages 1259-1273.
    3. Chen, Dan & Meng, Jinhao & Huang, Huanyang & Wu, Ji & Liu, Ping & Lu, Jiwu & Liu, Tianqi, 2022. "An Empirical-Data Hybrid Driven Approach for Remaining Useful Life prediction of lithium-ion batteries considering capacity diving," Energy, Elsevier, vol. 245(C).
    4. Fei, Zicheng & Yang, Fangfang & Tsui, Kwok-Leung & Li, Lishuai & Zhang, Zijun, 2021. "Early prediction of battery lifetime via a machine learning based framework," Energy, Elsevier, vol. 225(C).
    5. Ling, Ziye & Cao, Jiahao & Zhang, Wenbo & Zhang, Zhengguo & Fang, Xiaoming & Gao, Xuenong, 2018. "Compact liquid cooling strategy with phase change materials for Li-ion batteries optimized using response surface methodology," Applied Energy, Elsevier, vol. 228(C), pages 777-788.
    6. Pan, Yongjun & Zhang, Xiaoxi & Liu, Yue & Wang, Huacui & Cao, Yangzheng & Liu, Xin & Liu, Binghe, 2022. "Dynamic behavior prediction of modules in crushing via FEA-DNN technique for durable battery-pack system design," Applied Energy, Elsevier, vol. 322(C).
    7. Su, Shaosen & Li, Wei & Garg, Akhil & Gao, Liang, 2022. "An adaptive boosting charging strategy optimization based on thermoelectric-aging model, surrogates and multi-objective optimization," Applied Energy, Elsevier, vol. 312(C).
    8. Zhang, Xiaoxi & Xiong, Yue & Pan, Yongjun & Xu, Dongxin & Kawsar, Ibna & Liu, Binghe & Hou, Liang, 2023. "Deep-learning-based inverse structural design of a battery-pack system," Reliability Engineering and System Safety, Elsevier, vol. 238(C).
    9. Gandoman, Foad H. & Ahmadi, Abdollah & Bossche, Peter Van den & Van Mierlo, Joeri & Omar, Noshin & Nezhad, Ali Esmaeel & Mavalizadeh, Hani & Mayet, Clément, 2019. "Status and future perspectives of reliability assessment for electric vehicles," Reliability Engineering and System Safety, Elsevier, vol. 183(C), pages 1-16.
    10. Shabani, Masoume & Wallin, Fredrik & Dahlquist, Erik & Yan, Jinyue, 2022. "Techno-economic assessment of battery storage integrated into a grid-connected and solar-powered residential building under different battery ageing models," Applied Energy, Elsevier, vol. 318(C).
    11. Santhosh, T.V. & Gopika, V. & Ghosh, A.K. & Fernandes, B.G., 2018. "An approach for reliability prediction of instrumentation & control cables by artificial neural networks and Weibull theory for probabilistic safety assessment of NPPs," Reliability Engineering and System Safety, Elsevier, vol. 170(C), pages 31-44.
    12. Yao, Lei & Fang, Zhanpeng & Xiao, Yanqiu & Hou, Junjian & Fu, Zhijun, 2021. "An Intelligent Fault Diagnosis Method for Lithium Battery Systems Based on Grid Search Support Vector Machine," Energy, Elsevier, vol. 214(C).
    13. Cheng, Ziqiang & Tenny, Kevin M. & Pizzolato, Alberto & Forner-Cuenca, Antoni & Verda, Vittorio & Chiang, Yet-Ming & Brushett, Fikile R. & Behrou, Reza, 2020. "Data-driven electrode parameter identification for vanadium redox flow batteries through experimental and numerical methods," Applied Energy, Elsevier, vol. 279(C).
    14. Gandoman, Foad H. & Jaguemont, Joris & Goutam, Shovon & Gopalakrishnan, Rahul & Firouz, Yousef & Kalogiannis, Theodoros & Omar, Noshin & Van Mierlo, Joeri, 2019. "Concept of reliability and safety assessment of lithium-ion batteries in electric vehicles: Basics, progress, and challenges," Applied Energy, Elsevier, vol. 251(C), pages 1-1.
    15. Maitane Berecibar, 2019. "Machine-learning techniques used to accurately predict battery life," Nature, Nature, vol. 568(7752), pages 325-326, April.
    16. Anselma, Pier Giuseppe & Kollmeyer, Phillip & Lempert, Jeremy & Zhao, Ziyu & Belingardi, Giovanni & Emadi, Ali, 2021. "Battery state-of-health sensitive energy management of hybrid electric vehicles: Lifetime prediction and ageing experimental validation," Applied Energy, Elsevier, vol. 285(C).
    17. Tan, P. & Jiang, H.R. & Zhu, X.B. & An, L. & Jung, C.Y. & Wu, M.C. & Shi, L. & Shyy, W. & Zhao, T.S., 2017. "Advances and challenges in lithium-air batteries," Applied Energy, Elsevier, vol. 204(C), pages 780-806.
    18. Thelen, Adam & Li, Meng & Hu, Chao & Bekyarova, Elena & Kalinin, Sergey & Sanghadasa, Mohan, 2022. "Augmented model-based framework for battery remaining useful life prediction," Applied Energy, Elsevier, vol. 324(C).
    19. Che, Yunhong & Zheng, Yusheng & Wu, Yue & Sui, Xin & Bharadwaj, Pallavi & Stroe, Daniel-Ioan & Yang, Yalian & Hu, Xiaosong & Teodorescu, Remus, 2022. "Data efficient health prognostic for batteries based on sequential information-driven probabilistic neural network," Applied Energy, Elsevier, vol. 323(C).
    20. Solai, Elie & Guadagnini, Maxime & Beaugendre, Héloïse & Daccord, Rémi & Congedo, Pietro, 2022. "Validation of a data-driven fast numerical model to simulate the immersion cooling of a lithium-ion battery pack," Energy, Elsevier, vol. 249(C).
    21. Xiong, Rui & Sun, Wanzhou & Yu, Quanqing & Sun, Fengchun, 2020. "Research progress, challenges and prospects of fault diagnosis on battery system of electric vehicles," Applied Energy, Elsevier, vol. 279(C).
    Full references (including those not matched with items on IDEAS)

    Citations

    Citations are extracted by the CitEc Project, subscribe to its RSS feed for this item.
    as


    Cited by:

    1. Zhang, Xiaoxi & Pan, Yongjun & Zhou, Junxiao & Li, Zhixiong & Liao, Tianjun & Li, Jie, 2024. "Forward and reverse design of adhesive in batteries via dynamics and machine learning algorithms for enhanced mechanical safety," Reliability Engineering and System Safety, Elsevier, vol. 247(C).

    Most related items

    These are the items that most often cite the same works as this one and are cited by the same works as this one.
    1. Hu, Dunan & Huang, Sheng & Wen, Zhen & Gu, Xiuquan & Lu, Jianguo, 2024. "A review on thermal runaway warning technology for lithium-ion batteries," Renewable and Sustainable Energy Reviews, Elsevier, vol. 206(C).
    2. Zhang, Xiaoxi & Pan, Yongjun & Zhou, Junxiao & Li, Zhixiong & Liao, Tianjun & Li, Jie, 2024. "Forward and reverse design of adhesive in batteries via dynamics and machine learning algorithms for enhanced mechanical safety," Reliability Engineering and System Safety, Elsevier, vol. 247(C).
    3. Ren, Song & Sun, Jing, 2024. "Multi-fault diagnosis strategy based on a non-redundant interleaved measurement circuit and improved fuzzy entropy for the battery system," Energy, Elsevier, vol. 292(C).
    4. Li, Shuowei & Zhang, Caiping & Du, Jingcai & Zhang, Linjing & Jiang, Yan, 2025. "Feature engineering-driven multi-scale voltage anomaly detection for Lithium-ion batteries in real-world electric vehicles," Applied Energy, Elsevier, vol. 377(PC).
    5. Yu, Quanqing & Dai, Lei & Xiong, Rui & Chen, Zeyu & Zhang, Xin & Shen, Weixiang, 2022. "Current sensor fault diagnosis method based on an improved equivalent circuit battery model," Applied Energy, Elsevier, vol. 310(C).
    6. Du, Jingcai & Zhang, Caiping & Li, Shuowei & Zhang, Linjing & Zhang, Weige, 2024. "Aging abnormality detection of lithium-ion batteries combining feature engineering and deep learning," Energy, Elsevier, vol. 297(C).
    7. Kim, Seongyoon & Choi, Yun Young & Choi, Jung-Il, 2022. "Impedance-based capacity estimation for lithium-ion batteries using generative adversarial network," Applied Energy, Elsevier, vol. 308(C).
    8. Liu, Xutao & Tao, Shengyu & Fu, Shiyi & Ma, Ruifei & Cao, Tingwei & Fan, Hongtao & Zuo, Junxiong & Zhang, Xuan & Wang, Yu & Sun, Yaojie, 2024. "Binary multi-frequency signal for accurate and rapid electrochemical impedance spectroscopy acquisition in lithium-ion batteries," Applied Energy, Elsevier, vol. 364(C).
    9. Ospina Agudelo, Brian & Zamboni, Walter & Monmasson, Eric, 2021. "Application domain extension of incremental capacity-based battery SoH indicators," Energy, Elsevier, vol. 234(C).
    10. Chang, Chun & Wang, Qiyue & Jiang, Jiuchun & Jiang, Yan & Wu, Tiezhou, 2023. "Voltage fault diagnosis of a power battery based on wavelet time-frequency diagram," Energy, Elsevier, vol. 278(PB).
    11. Wang, Shuhui & Wang, Zhenpo & Cheng, Ximing & Zhang, Zhaosheng, 2023. "A double-layer fault diagnosis strategy for electric vehicle batteries based on Gaussian mixture model," Energy, Elsevier, vol. 281(C).
    12. Shen, Dongxu & Lyu, Chao & Yang, Dazhi & Hinds, Gareth & Wang, Lixin, 2023. "Connection fault diagnosis for lithium-ion battery packs in electric vehicles based on mechanical vibration signals and broad belief network," Energy, Elsevier, vol. 274(C).
    13. Gandoman, Foad H. & Jaguemont, Joris & Goutam, Shovon & Gopalakrishnan, Rahul & Firouz, Yousef & Kalogiannis, Theodoros & Omar, Noshin & Van Mierlo, Joeri, 2019. "Concept of reliability and safety assessment of lithium-ion batteries in electric vehicles: Basics, progress, and challenges," Applied Energy, Elsevier, vol. 251(C), pages 1-1.
    14. Li, Alan G. & West, Alan C. & Preindl, Matthias, 2022. "Towards unified machine learning characterization of lithium-ion battery degradation across multiple levels: A critical review," Applied Energy, Elsevier, vol. 316(C).
    15. Song, Dengwei & Cheng, Yujie & Zhou, An & Lu, Chen & Chong, Jin & Ma, Jian, 2024. "Remaining useful life prediction and cycle life test optimization for multiple-formula battery: A method based on multi-source transfer learning," Reliability Engineering and System Safety, Elsevier, vol. 249(C).
    16. Lv, Haichao & Kang, Lixia & Liu, Yongzhong, 2023. "Analysis of strategies to maximize the cycle life of lithium-ion batteries based on aging trajectory prediction," Energy, Elsevier, vol. 275(C).
    17. Foad H. Gandoman & Emad M. Ahmed & Ziad M. Ali & Maitane Berecibar & Ahmed F. Zobaa & Shady H. E. Abdel Aleem, 2021. "Reliability Evaluation of Lithium-Ion Batteries for E-Mobility Applications from Practical and Technical Perspectives: A Case Study," Sustainability, MDPI, vol. 13(21), pages 1-24, October.
    18. Huang, Zhiliang & Wang, Huaixing & Gan, Zhouwang & Yang, Tongguang & Yuan, Cong & Lei, Bing & Chen, Jie & Wu, Shengben, 2024. "An mechanical/thermal analytical model for prismatic lithium-ion cells with silicon‑carbon electrodes in charge/discharge cycles," Applied Energy, Elsevier, vol. 365(C).
    19. Sun, Zhenyu & Han, Yang & Wang, Zhenpo & Chen, Yong & Liu, Peng & Qin, Zian & Zhang, Zhaosheng & Wu, Zhiqiang & Song, Chunbao, 2022. "Detection of voltage fault in the battery system of electric vehicles using statistical analysis," Applied Energy, Elsevier, vol. 307(C).
    20. Hou, Jing & Su, Taian & Gao, Tian & Yang, Yan & Xue, Wei, 2025. "Early prediction of battery lifetime for lithium-ion batteries based on a hybrid clustered CNN model," Energy, Elsevier, vol. 319(C).

    More about this item

    Keywords

    ;
    ;
    ;
    ;
    ;
    ;

    Statistics

    Access and download statistics

    Corrections

    All material on this site has been provided by the respective publishers and authors. You can help correct errors and omissions. When requesting a correction, please mention this item's handle: RePEc:eee:appene:v:357:y:2024:i:c:s0306261923018457. See general information about how to correct material in RePEc.

    If you have authored this item and are not yet registered with RePEc, we encourage you to do it here. This allows to link your profile to this item. It also allows you to accept potential citations to this item that we are uncertain about.

    If CitEc recognized a bibliographic reference but did not link an item in RePEc to it, you can help with this form .

    If you know of missing items citing this one, you can help us creating those links by adding the relevant references in the same way as above, for each refering item. If you are a registered author of this item, you may also want to check the "citations" tab in your RePEc Author Service profile, as there may be some citations waiting for confirmation.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: Catherine Liu (email available below). General contact details of provider: http://www.elsevier.com/wps/find/journaldescription.cws_home/405891/description#description .

    Please note that corrections may take a couple of weeks to filter through the various RePEc services.

    IDEAS is a RePEc service. RePEc uses bibliographic data supplied by the respective publishers.