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Outline
Concluding Remarks
Cooling Concept Development and Validation Module and Pack Level Thermal and Flow Analysis
Nonlinear Statics
Mechanical shock, pothole, and drop analysis Nonlinear and contact analysis
Snap-in/pull-out force estimation Jack loading analysis Bolt assembly, module pressure plate, etc.
LS-DYNA3D ABAQUS (Implicit/Explicit) Access to other software through HyperWorks Partner Alliance License
nCode DesignLife Key to Metals Others
Challenges
A few locations on mounting brackets showed fatigue cracks Initial random vibration stress analysis showed the failure locations have high RMS stress during vibration events, but it cannot accurately quantify the fatigue life The fatigue properties for the metal components were unknown Project timing and budget wont allow performing material test to obtain the fatigue properties
Result Comparisons
With correlated fatigue properties, the analysis identified all test failure locations:
The failure locations have relatively high RMS stresses comparing to material specs The fatigue lives in these locations are lower than the requirement
3 RMS stress : 55% of material uts Fatigue life: 90% of the required life
3 RMS stress: 72% of material uts Fatigue life: 10% of required life
New pack design passed the random vibration fatigue analysis These design changes were implemented and the new pack went through random vibration test without fatigue issue
Infinite
65 li es
Detailed model
Each component is modeled in detail with corresponding material properties End plate is modeled in detail with shell elements Module bolt is modeled with beam elements
Endplate modeled in detail by shell element Bolt was modeled by beam element with rod section Cell, heat sink, cell compliance pad, band were homogenized into a 3-d orthotropic material Local coordinate system was used for the orthotropic material modeling
For free-free boundary condition, the first 3 modes from test were used for FEA model correlation For fixed boundary condition, the first 5 modes from test were used in FEA model correlation Homogenized orthotropic material was formulated using the following engineering constants
Goal was to adjust E1, E2, E3, G12, G13, G23 to correlate both the mode shapes and frequencies with test results. Observations during initial evaluation:
Some Eii, Gij, and vij have strong influence to long and medium size modules modal frequencies; Other Eii, Gij, and vij have significant effect to small module modal frequencies The remaining Eii, Gij, and vij have little effect to the first 3 modal frequencies at all. In that case, they are assigned to zero, leading to a simple material matrix
Material parameters were first manually adjusted to match modal shapes in order. Then HyperStudy was used to match first 3 frequencies more closely
Modal Correlation
HyperStudy
Modal Correlation
HyperStudy
Modal Correlation
HyperStudy
Results Correlations
Table-1: Relative Deviations of Estimated Modal Frequencies from Test Results under free-free condition
Table-2: Relative Deviations of Estimated Modal Frequencies from Test Results under fixed condition
This hybrid module model was a compromise among all 3 size modules, with deviation within 5% in free-free boundary condition The hybrid module model was more skewed to large size modules because for small size modules, the first frequency is very high already, making them less sensitive to external vibration. By using such approach, a battery module for pack analysis can be quickly modeled and still achieve good analytical results
Concluding Remarks
A123 has a broad range of engineering simulation capabilities to support battery pack/module development activities Altairs HyperWorks Suite and HWPA are the best cost-effective tools to match A123s FEA simulation requirements