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

Author

Listed:
  • Feng Zhu

    (Hopkins Extreme Materials Institute (HEMI), Johns Hopkins University, 3400 N. Charles Street, Baltimore, MD 21218, USA
    Department of Mechanical Engineering, 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)

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.

Suggested Citation

  • Feng Zhu & Runzhou Zhou & David J. Sypeck, 2020. "Numerical Modeling and Safety Design for Lithium-Ion Vehicle Battery Modules Subject to Crush Loading," Energies, MDPI, vol. 14(1), pages 1-24, December.
    • Handle: RePEc:gam:jeners:v:14:y:2020:i:1:p:118-:d:469494
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    References listed on IDEAS

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    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. Golriz Kermani & Elham Sahraei, 2017. "Review: Characterization and Modeling of the Mechanical Properties of Lithium-Ion Batteries," Energies, MDPI, vol. 10(11), pages 1-25, October.
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    1. Yu, Quanqing & Nie, Yuwei & Peng, Simin & Miao, Yifan & Zhai, Chengzhi & Zhang, Runfeng & Han, Jinsong & Zhao, Shuo & Pecht, Michael, 2023. "Evaluation of the safety standards system of power batteries for electric vehicles in China," Applied Energy, Elsevier, vol. 349(C).

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