For EV’s, battery pack packaging plays critical role to balance the intrusion and crushability of vehicle under side crash scenarios. Battery side rail design and optimization is a key element in preventing the damage to High Voltage (HV) components and Li-ion Cells during side pole impact conditions (Renew Sustain Energy Rev 60:1319–1331, 2016). For Hybrid Electric vehicle (HEV) body structure optimization is done as demonstrated in this paper (Christensen et al. in Int J Veh Struct Syst 3(2), 2011). But most of the Battery Electric vehicle (BEV) involve packaging battery under the seats and mounted to vehicle rocker. During side impact, apart from body sill, battery side rail member also participates in load path enabling the high energy absorption as shown in Fig. 1. Goal is to transfer the loads from vehicle rocker, in case of side pole impact, to battery enclosure without exceeding allowable intrusion to inner wall of battery cover/tray to prevent direct contact with HV components. Packaging of HV components, modules and other electronics highly depends on vehicle architecture and will be designed at early stage of vehicle development. One of the mass-effective side rail solutions involve using extruded Aluminum structure for Battery packs. This paper proposes a method of combining the linear topology using represented cross section of side rail (to study load path and identify critical members in extrusion) followed by a non-linear gauge optimization using a buck model and summarize the benefits in computational efficiency and ease of considering multiple loading into side rail compared to conventional topology optimization with subsystem model.


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    Title :

    Optimization of Aluminum Extrusion Battery Side Rail for Crashworthiness


    Additional title:

    Lect.Notes Mechanical Engineering



    Conference:

    National Conference on Multidisciplinary Analysis and Optimization ; 2021 October 07, 2021 - October 09, 2021



    Publication date :

    2022-09-25


    Size :

    6 pages





    Type of media :

    Article/Chapter (Book)


    Type of material :

    Electronic Resource


    Language :

    English




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