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3DS
.CO
M©
Das
saul
tS
ystè
mes
| Con
fiden
tial
Info
rmat
ion
| 11/
6/20
17| r
ef.:
3D
S_D
ocum
ent_
2015 Vibration Fatigue Analysis of
Battery Pack
Dassault Systemes Korea
Jeon, Hojin
2
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IMU
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Introduction
Steady state dynamic analysis using Abaqus
PSD Fatigue analysis using fe-safe
Bead optimization using Tosca
Summary
Contents
3DS
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M©
Das
saul
tS
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| 11/
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17| r
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3D
S_D
ocum
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2015 Introduction
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Thermal Performance Crush
Battery Cell Level Battery Module Level Battery Pack Level Full Car Level
Battery Simulation for Electric Vehicle
External Impact NVHImage ref. : www.gm.com
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Random Vibration Test for Battery Pack
Image ref. : www.rsp.coo.kr
X-direction
Y-direction
Z-direction
Frequency [Hz]
PSD
[G
2/H
z]
Shaker test bench Test condition(ISO12405-3)
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Vibration fatigue analysis using PSD
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Simulation Workflow
5
3
1
Frequency analysis SSD analysis
Fatigue analysis from PSD
Bead optimization
Abaqus fe-safe
Tosca
2
Frequency analysis Steady state dynamic
analysis
Fatigue analysis from PSD
Abaqus fe-safe
4
Optimization
analysis
Initial analysisDesign
Optimization
3DS
.CO
M©
Das
saul
tS
ystè
mes
| Con
fiden
tial
Info
rmat
ion
| 11/
6/20
17| r
ef.:
3D
S_D
ocum
ent_
2015 Steady state dynamic analysis
using Abaqus
9
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Battery pack assembly
Battery Cell(pouch Type)
Battery Module Battery Pack Electric Car
Image ref. : www.gm.com
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Simulation model
Battery ModuleBattery Cell(size 170 x 200 x 60 mm)
Battery Module(size : 270 x 250 x 210 mm)
Battery Pack
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Materials
Part Name Material
1 Battery Cell Equivalent Material
3 Battery Module Bottom Plate Steel
4 Battery Module Frame Glass Fiber 30%
5 Battery Module Front Cover Steel
6 Battery Module Top Cover Steel
7 Battery Module Upper Plate Steel
8 Battery Pack Bottom Cover Steel
9 Battery Pack Top Cover Steel
10 Battery Module Cooling Plate Aluminum
11 Bolt Steel
12 Shaft Steel
Battery Module Cover
Battery Module Front Cover
Battery Module Plate
Battery Module Frame
Bolt
Battery CELL
Battery Module Bottom Plate
Shaft
12
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Frequency analysis
Boundary condition
Fixed holes for mounting
Top view
Mode Frequency (Hz)
1 38.446
2 42.448
3 53.599
4 119.04
5 158.32
6 173.33
7 181.10
Results
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Frequency analysis
1st mode (38.446 Hz) 2nd mode (42.448 Hz) 3rd mode (58.599 Hz)
Battery Pack
Bottom Cover
Results
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015 Results
Steady state dynamic analysis
3rd mode(58.59Hz)71MPa
3DS
.CO
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Das
saul
tS
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| Con
fiden
tial
Info
rmat
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| 11/
6/20
17| r
ef.:
3D
S_D
ocum
ent_
2015 PSD fatigue analysis
using fe-safe
16
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Methodology for vibration fatigue from PSD
Abaqus
fe-safe
User Input
Frequency
Analysis
Mode-based
SSD with Unit
Response
Frequency
Response
Function
PSD Matrix
From Standard
von Mises
PSD
Calculation of
Rainflow rangeLIFE
DAMAGE
Abaqus fe-safe
SN curve
Sherrat-Dirlik method
17
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Fatigue analysis from PSDResults
71MPaFatigue life:
185回
Steady state dynamic Fatigue analysis
3DS
.CO
M©
Das
saul
tS
ystè
mes
| Con
fiden
tial
Info
rmat
ion
| 11/
6/20
17| r
ef.:
3D
S_D
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2015 Bead optimization using Tosca
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Effect of Bead
Deflection of Beam without Bead : 100%
Deflection of Beam with Bead : 10%
Initial State without Bead Design Optimization with bead
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Tosca/structure in Abaqus/CAE
Optimization Task
Design Response
Objective Function
Constraint
Tosca/structure in Abaqus/CAE Bead optimization
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Bead Optimization
Optimization region
Bottom plate of battery pack
Design response and Objective function
• Design response: natural frequency of mode 3
• Objective function: Maximize design response
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015 Results
Bead Optimization
53.94Hz 58.75Hz 78.55Hz 100.96Hz53.59Hz
initial 1st iteration 2nd iteration 3rd iteration 4th iteration
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015 Results of SSD
Bead Optimization
Initial design Optimization design
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DS
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015 Results of Fatigue analysis
Bead Optimization
Fatigue life:
21,350回Fatigue life:
185回
Initial design Optimization design
3DS
.CO
M©
Das
saul
tS
ystè
mes
| Con
fiden
tial
Info
rmat
ion
| 11/
6/20
17| r
ef.:
3D
S_D
ocum
ent_
2015 Summary
26
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Summary
The workflow for vibration fatigue analysis using PSD was introduced.
Fatigue life was predicted by using PSD input and fe-safe after frequency analysis and steady-state
dynamic in Abaqus.
Bead optimization in Tosca was used to improve the design of the predicted failure at the initial
design stage.
27
3DS
.CO
M©
Das
saul
tS
ystè
mes
| Con
fiden
tial
Info
rmat
ion
| 11/
6/20
17| r
ef.:
3D
S_D
ocum
ent_
2015