Copertina

Coupled Electro-Thermal FEM with Geometric Symmetry Constraints for Modular Battery Pack Design

Salvato in:
Pubblicato in:Symmetry vol. 17, no. 6 (2025), p. 865-890
Autore principale: Liu Yingshuai
Altri autori: Liu Chenxing, Tan, Jianwei, Tian Guangdong
Pubblicazione:
MDPI AG
Soggetti:
China
Load
Finite element method
Risk management
Performance evaluation
Optimization techniques
Electric vehicles
Topology
Structural steels
Energy
Outdoor air quality
Killed steels
Impact strength
Symmetry
Stress distribution
Efficiency
Design techniques
Asymmetry
Design optimization
Carbon fibers
Structural integrity
Temperature gradients
Working conditions
Resonant frequencies
Weight reduction
Automobile industry
Finite element analysis
Performance characteristics
Constraints
Aluminum base alloys
Structural stability
Accesso online:Citation/Abstract
Full Text + Graphics
Full Text - PDF
Tags: Aggiungi Tag
Nessun Tag, puoi essere il primo ad aggiungerne!!
Abstract:This study investigates the structural integrity and dynamic behavior of symmetry-optimized battery pack systems for new energy vehicles through advanced finite element analysis. It examines symmetry-optimized battery pack systems with mechanically stable and thermally adaptive potentials. Leveraging geometric symmetry principles, a high-fidelity three-dimensional (3D) model was constructed in SolidWorks 2023 and subjected to symmetry-constrained static analysis on ANSYS Workbench 2021 R1 platform. The structural performance was systematically evaluated under three critical asymmetric loading scenarios: emergency left/right turns and braking conditions, with particular attention to symmetric stress distribution patterns. The numerical results confirmed the initial design’s compliance with mechanical requirements while revealing symmetric deformation characteristics in dominant mode shapes. Building upon symmetry-enhanced topology configuration, a novel lightweight strategy was implemented by substituting Q235 steel with ZL104 aluminum alloy. While mechanical symmetry has been widely studied, thermal gradients in battery packs can induce asymmetric expansions. For example, uneven cooling may cause localized warping in aluminum alloy shells. This multiphysics effect must be integrated into symmetry constraints to ensure true stability. Symmetric material distribution optimization reduced the mass by 19% while maintaining structural stability, as validated through comparative static and modal analyses. Notably, the symmetric eigenfrequency arrangement in optimized modules effectively avoids common vehicle excitation bands (8–12 Hz/25–35 Hz), demonstrating significant resonance risk reduction through frequency redistribution. This research establishes a symmetry-driven design paradigm that systematically coordinates structural efficiency with dynamic reliability, providing critical insights for developing next-generation battery systems with balanced performance characteristics.
ISSN:2073-8994
DOI:10.3390/sym17060865
Fonte:Engineering Database