Abstract
Improvement in electric vehicle technology requires the lithium-ion battery system’s safe operations, protecting battery fire damage potential from road debris impact. In this research a design of sandwich panel construction with a lattice structure core is evaluated as the battery protection system. Additive manufacturing technology advancements have paved the way for lattice structure development. The sandwich protective structure designs are evaluated computationally using a non-linear dynamic finite element analysis for various geometry and material parameters. The lattice structure’s optimum shape was obtained based on the highest Specific Energy Absorption (SEA) parameter developed using the ANOVA and Taguchi robust design method. It is found that the octet-cross lattice structure with 40% relative density provided the best performance in terms of absorbing impact energy. Furthermore, the sandwich panel construction with two layers of lattice structure core performed very well in protecting the lithium-ion NCA battery in the ground impact loading conditions, which the impactor velocity is 42 m/s, representing vehicle velocity in highway, and weigh 0.77 kg. The battery shortening met the safety threshold of less than 3 mm deformation.
Highlights
Published: 29 December 2021Global development of electric vehicle (EV) technology is progressed rapidly
This paper studied the sandwich structure as a battery protection system using a lattice structure as the core due to the need to protect the battery and the lattice structure’s properties
The results show that all control factors are statistically significant to the single-cell lattice structure’s Specific Energy Absorption (SEA) performance
Summary
Global development of electric vehicle (EV) technology is progressed rapidly. According to McKinsey, EV sales from 2010 until 2017 are always increasing, reaching a new milestone of 1 million units sold in 2017 [1]. EV had been sold for approximately 4.3 million YTD, and it is expected that by the end of 2021, the sales will exceed 6 million vehicles [2]. The EV has a higher efficiency compared to common internal combustion engine vehicle due to electrical components usage and minimal power conversion [4]. Most electric vehicles use the lithium-ion battery as the primary power source due to its high energy density and battery’s long lifespan [5,6]. The battery is good for the environment, there are still potential hazards to the passengers. Battery fires cause several accidents, for example, the Chevrolet Volt accident in May 2011 and the Tesla Model
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