基于载荷谱的电池包疲劳试验与计算方法

doi:10.12141/j.issn.1000-565X.230063

摘要/Abstract

摘要：

电池包作为电动汽车的核心部件之一，对电动汽车的整车性能有着关键性的影响。而在电动汽车的运行过程中，电池包会不断受到来自路面的持续性冲击力，造成电池包的疲劳损坏，对驾驶员和乘客的安全以及整车性能造成一定的影响。本文以电动汽车电池包为研究对象，建立了电池包随机振动试验方法与疲劳寿命的计算方法。先对振动台、工装夹具和电池包进行扫频分析，得到振动台台面、夹具空载端板、电池包与工装夹具连接端板处的加速度传感器的测量数值与输入扫频加速度值保持一致，验证振动信号的有效传递，确保输入的振动信号能够准确传递至电池包，然后开展电池包随机振动试验。并对电池包进行了电芯性能检测、气密性检查、绝缘电阻检查和共振频率检查，得出电池包的损伤部位。研究了电池包疲劳损伤计算方法，对电池箱、电池模组和电池包内各连接方式进行了精细化建模。基于精细化模型，进行了电池包频响特性的计算。基于计算得到的频响特性和实车路谱采集试验得到电池包随机振动载荷谱曲线，采用Goodman疲劳寿命估算方法和Miner线性累积损伤法则，并结合电池包材料S-N曲线，对电池包进行了随机振动疲劳损伤分析。试验得到的电池包结构损伤部位与分析得到的失效部位具有较好的一致性，证实了本文提出的疲劳损伤计算方法的准确性。

关键词: 电动汽车, 电池包, 随机振动试验, 精细化模型, 疲劳损伤计算

Abstract:

As one of the core components of electric vehicles, battery package has a critical impact on the overall performance of the electric vehicle. During the operation of electric vehicles, the battery package is constantly subjected to continuous impact from the road, causing fatigue damage to the battery package, which affects the safety of drivers and passengers as well as the performance of the whole vehicle. Taking battery package of electric vehicles as research object, this study established random vibration test method and calculation method for fatigue life of battery package. Firstly, it carried out frequency sweep analysis on Shaker table, fixture and battery package, and obtained the values of the acceleration sensors at shaker table surface, fixture unloaded end plate, and the connection end plate between battery package and fixture, which were consistent with the input frequency sweep acceleration values, verifying the effective transmission of the vibration signal and ensuring that the input vibration signal can be accurately transmitted to the battery package. After that, random vibration test of battery package was carried out. Cell performance testing, air tightness inspection, insulation resistance inspection, and resonance frequency inspection on the battery package were conducted and the damaged parts of battery package were obtained. The calculation method of battery pack fatigue damage was studied, and the battery box, battery module and battery pack were finely modeled. Based on the fine modeling, frequency response of battery package was analyzed. Based on the results of frequency response analysis and the random vibration load spectrum curve of the battery package obtained from the vehicle road spectrum acquisition test, and combined with the S-N curve of the battery pack material, random vibration fatigue life of battery package was analyzed under load spectrum by using Goodman fatigue life estimation method and Miner linear cumulative damage rule. The damage positions of battery package obtained from the test are in good agreement with the failure positions obtained from the analysis, which confirms the accuracy of the fatigue life calculation method proposed in this paper.

Key words: electric vehicle, battery package, random vibration test, fine modeling, fatigue life calculation

中图分类号:

U461.7

上官文斌, 岳炼, 吕辉, 等. 基于载荷谱的电池包疲劳试验与计算方法[J]. 华南理工大学学报(自然科学版), 2024, 52(3): 50-56.

SHANGGUAN Wenbin, YUE Lian, LÜ Hui, et al. Fatigue Test and Calculation Methods for Battery Package Based on Load Spectrum[J]. Journal of South China University of Technology(Natural Science Edition), 2024, 52(3): 50-56.

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参考文献 14

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位置	振动前共振频率/Hz	振动后共振频率/Hz	差值/Hz
B1传感器	51.0	48.2	2.8
	64.5	61.1	3.4
	162.3	158.4	3.9
B2传感器	49.1	47.7	1.4
	64.9	61.1	3.8
	192.5	186.2	6.3
B3传感器	64.0	60.1	3.9
	82.2	81.1	1.1
	161.3	158.0	3.3

位置	振动后共振频率/Hz	振动前共振频率/Hz	差值/Hz
B1传感器	86.5	94.7	8.2
B2传感器	68.8	77.4	8.6
	88.4	95.1	6.7
	249.0	247.6	1.4
B3传感器	86.0	94.2	8.2

电池包	方向	试验损伤部位	仿真结果	试验结果
A号	X	无	安全	通过
B号	Y	无	安全	通过
C号	Z	托架与下箱体搭接处	失效	开裂
		后部挂载与箱体连接处	失效	开裂
		上盖前部凸起与后部过渡处	失效	开裂
		托架与右挂载盖板处	安全	开裂

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