Journal of South China University of Technology(Natural Science) >

2024 , Vol. 52 >Issue 3: 50 - 56

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

Mechanical Engineering

Fatigue Test and Calculation Methods for Battery Package Based on Load Spectrum

Expand
  • 1.School of Mechanical and Automotive Engineering，South China University of Technology，Guangzhou 510640，Guangdong，China
    2.Lucky Harvest Co. ，Ltd. ，Dongguan 523870，Guangdong，China
上官文斌（1963-），男，博士，教授，主要从事汽车振动控制研究。E-mail： sgwb@scut.edu.cn

Received date: 2023-02-22

  Online published: 2023-03-30

Supported by

the National Natural Science Foundation of China(12272137)

Fold

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

Cite this article

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), 2024 , 52(3) : 50 -56 . DOI: 10.12141/j.issn.1000-565X.230063

References

1 HUA X， THOMAS A ．Effect of dynamic loads and vibrations on lithium-ion batteries［J］．Journal of Low Frequency Noise，Vibration and Active Control，2021，40（4）：1927-1934.
2 KIM H， KIM G， JI W，et al ．Random vibration fatigue analysis of a multi-material battery pack structure for an electric vehicle［J］．Functional Composites and Structures，2021，3（2）：025006.
3 戴江梁，熊飞，刘静，等 ．基于某车型动力电池包的随机振动疲劳分析与结构设计改进［J］．机械强度，2020，42（5）：1266-1270.
  DAI Jiangliang， XIONG Fei， LIU Jing，et al ．Random vibration fatigue analysis and structural design improvement based on a vehicle power battery pack［J］．Journal of Mechanical Strength，2020；42（5）：1266-1270.
4 王文伟，程雨婷，姜卫远，等 ．电动汽车电池箱结构随机振动疲劳分析［J］．汽车工程学报，2016，6（1）：10-14.
  WANG Wenwei， CHENG Yuting， JIANG Weiyuan，et al ．Random vibration fatigue analysis of battery box structure of electric vehicle［J］．Chinese Journal of Automotive Engineering，2016，6（1）：10-14.
5 ZHANG L， MU Z， GAO X ．Coupling analysis and performance study of commercial 18650 lithium-ion batteries under conditions of temperature and vibration［J］．Energies，2018，11（10）：28-56.
6 HOOPER J M， MARCO J， CHOUCHELAMANE G H，et al ．Multi-axis vibration durability testing of lithium ion 18650 NCA cylindrical cells［J］．Journal of Energy Storage，2018，15：103-123.
7 BRAND M J， SCHUSTER S F， BACH T，et al ．Effects of vibrations and shocks on lithium-ion cells［J］．Journal of Power Sources，2015，288：62-69.
8 SWORNOWSKI P J ．Destruction mechanism of the internal structure in Lithium-ion batteries used in aviation industry［J］．Energy，2017，122：779-786.
9 CHOI Y， JUNG D，HAM K，et al ．A study on the accelerated vibration endurance tests for battery fixing bracket in electrically driven vehicles［J］．Procedia Engineering，2011，10：851-856.
10 LIU R， HOU Z， WANG S，et al ．Analysing vibration environment of a power battery in a running electric vehicle［J］．International Journal of Electric and Hybrid Vehicles，2021，13（1）：1-20.
11 SAHRAEI E， HILL R， WIERZBICKI T ．Calibration and finite element simulation of pouch lithium-ion batteries for mechanical integrity［J］．Journal of Power Sources，2012，201：307-321.
12 SU S， AKKARA F J， THAPER R，et al ．A state-of-the-art review of fatigue life prediction models for solder joint［J］．Journal of Electronic Packaging，2019，141（4）：040802.
13 LUO P， YAO W， SUSMEL L，et al ．Prediction methods of fatigue critical point for notched components under multiaxial fatigue loading［J］．Fatigue & Fracture of Engineering Materials & Structures，2019，42（12）：2782-2793.
14 LUO P， YAO W， WANG Y，et al ．A survey on fatigue life analysis approaches for metallic notched components under multi-axial loading［J］．Proceedings of the Institution of Mechanical Engineers，Part G：Journal of Aerospace Engineering，2019，233（10）：3870-3890.
Options
Outlines

/

〈 〉