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Multi-physics FE models (indicated by squares) and simulation cases (indicated by rounded squares) developed in this work.
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![Vehicle crash safety FE models developed by the CCSA team [55]. The...](publication/383488484/figure/fig2/AS:11431281280680517@1727518278645/Vehicle-crash-safety-FE-models-developed-by-the-CCSA-team-55-The-models-with-were_Q320.jpg)
The safety of lithium-ion batteries is critical to the safety of battery electric vehicles (BEVs). The purpose of this work is to develop a method to predict battery thermal runaway in full electric vehicle crash simulation. The thermal–electrical–mechanical-coupled finite element analysis is used to model an individual lithium-ion battery cell, a...
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Citations
... Second, battery safety evaluations often assess enclosure integrity in isolation, neglecting its synergistic role within the vehicle's crash energy management system [12][13][14]. Although emerging efforts-such as integrated BIW-battery simulations for passenger EVs [15][16][17][18]-have shown promise, they remain constrained by two significant gaps: (1) existing integrated models are primarily validated for passenger vehicles, despite fundamental design divergences in electric micro commercial vehicles (E-MCVs); and (2) current frameworks inadequately address the conflicting demands of battery protection and cargo-oriented structural rigidity in E-MCVs. ...
This study presents a novel optimization framework applying the multi-objective response surface method to enhance the safety of electric micro commercial vehicles (E-MCVs) during side pole impacts. By focusing on seven critical load-bearing components, including the B-pillar and door frame beam, we achieved a 2% reduction in component weight while significantly improving energy absorption by 22.2%. The optimization led to a substantial decrease in intrusion, with B-pillar abdominal intrusions reduced by 22.5% and lower threshold intrusions down by 26.3%. Despite these improvements, challenges remained regarding battery pack deformation. To address this, we proposed two innovative solutions: strengthening the side longitudinal beams and integrating a bionic thin-walled energy-absorbing structure. These approaches effectively reduced side intrusions of the battery pack by 43.5% to 43.8%, with the bionic structure showing superior performance in weight management. However, the manufacturing feasibility and cost implications of the bionic design necessitate further exploration. The innovation in this study lies in the dual application of a response surface optimization method for load-bearing components and the integration of biomimetic design principles, significantly advancing collision safety for E-MCVs while providing new insights into the weight-efficient safety design.
... However, validating performance through extensive prototype development and experimental testing is not only time-and cost-intensive but also faces limitations in directly observing internal components or evaluating the effects of various conditions. To overcome these challenges, the finite element method (FEM) has emerged as a vital tool for research and development [15][16][17][18][19][20]. The FEM enables the simulation of the complex structural behavior and physical phenomena occurring under diverse driving conditions in EVs. ...
With the growing concerns over global warming and abnormal weather patterns, the development of eco-friendly technologies has emerged as a critical research area in the transportation industry. In particular, the global automotive market, one of the most widely used sectors, has witnessed a surge in research on electric vehicles (EVs) in line with these trends. Compared to traditional internal combustion engine vehicles, EVs require components with high strength and durability to achieve optimal performance. This study focuses on the development of a constant velocity (CV) joint, a critical component for reliably transmitting the maximum output of an electric vehicle motor. Unlike conventional numerical methods, the proposed thermo-mechanical coupled analysis simultaneously accounts for thermal and mechanical interactions, providing more realistic operational performance predictions. This analysis, conducted using the thermal modules of Ls-Dyna and ANSYS Mechanical, effectively simulated field operation scenarios. Prototype testing under simulated conditions showed a 6% discrepancy compared to numerical predictions, validating the high accuracy and reliability of the proposed method. This robust thermo-mechanical coupled analysis is expected to improve the durability and reliability of CV joint designs, advancing electric vehicle component development.
