Multi‐objective optimization of lithium‐ion battery pack casing for electric vehicles: Key role of materials design and their influence

Abstract

The battery box is the structure that comprises the battery cells and its casing. It is designed to fix and protect the battery module. During the actual driving, there exists stress and resonance on a battery pack and its outer casing due to external vibration and shock. The safety of an electric vehicle largely depends on the mechanical characteristics of its battery pack. Besides, a lighter weight electric vehicle has a longer driving range, which makes it much more popular in vehicle market. In this paper, a comprehensive design procedure based on multi-objective optimization and experiments is applied to compare the maximum equivalent stress and resonance frequency on a battery pack casing with different materials (DC01 steel, aluminum 6061, copper C22000, and carbon nanotube [CNT]) under bumpy road, sharp turns, and sudden braking conditions to obtain the best material. Moreover, CNT is proved to be the best material considering all the performance standards. Response surface optimization design method is adopted to get an optimal design of the battery pack casing. Optimization results conclude that the maximum equivalent stress can be reduced from 3.9243 to 3.2363 MPa, and the six-order resonance frequency can be increased from 722.65 to 788.71 Hz. Experiments are carried to validate the mechanical performance of the optimal design; the deviation between the simulation and experimental results is within the tolerance.

Behavior Analysis of a Flexure Hinge Array

“…For instance, particle swarm optimization (PSO) and genetic algorithm (GA) were combined with artificial neural network to predict the pile bearing capacity [37]. Multiobjective genetic algorithm was applied to optimize the thermal process of battery [38] and NSGA-II was used to optimize the optimization design of battery [39]. A design optimization was implemented by ANSYS workbench to optimize operation parameters of a photovoltaic thermal system integrated with natural zeolite [40].…”

An experimental investigation of liquid cooling scheduling for a battery module

“…2,3 Inconsistency between single cells limits the actual available capacity, voltage, and other performance parameters, and the overheating of one cell also speeds up the other cells' temperature rising. 4 To solve this problem, the temperature deviation of a battery module needs to be controlled within 5 C. [5][6][7] Thermal runaway causes the most severe safety problem, even catastrophic damage in large lithium-ion energy storage devices because of mismanagement, such as fire and combustion, 8,9 which results from drastic or successive reaction. The mechanism of these reactions includes decomposition of solid electrolyte interface (SEI), decomposition of cathode material and electrolyte, and reactions between anode and electrolyte.…”

“…Thermal runaway causes the most severe safety problem, even catastrophic damage in large lithium‐ion energy storage devices because of mismanagement, such as fire and combustion, which results from drastic or successive reaction. The mechanism of these reactions includes decomposition of solid electrolyte interface (SEI), decomposition of cathode material and electrolyte, and reactions between anode and electrolyte .…”

A thermal‐structure coupled optimization study of lithium‐ion battery modules with mist cooling

“…As the primary power supply of electric vehicles (EVs), the battery pack dramatically influences the performance of EV. 1 Lithium-ion batteries have received wide application in EV due to its superiorities: (a) higher power density, (b) lower self-discharging rate, and (c) longer cycle-life. 2,3 However, the electrochemical properties of a battery pack depends on the ambient temperature.…”

“…As a significant solution to lessen the overreliance on oil in modern industry, the sustainable vehicle has become a hot topic in transportation and energy research. As the primary power supply of electric vehicles (EVs), the battery pack dramatically influences the performance of EV 1 . Lithium‐ion batteries have received wide application in EV due to its superiorities: (a) higher power density, (b) lower self‐discharging rate, and (c) longer cycle‐life 2,3 .…”