Battery Pack and Underbody: Integration in the Structure Design for Battery Electric Vehicles—Challenges and Solutions
<p>Comparison between different lithium battery cells, different casing external shapes ((<b>a</b>)—cylindrical; (<b>b</b>)—brick; (<b>c</b>)—pouch) and related storage capacities [<a href="#B13-vehicles-05-00028" class="html-bibr">13</a>].</p> "> Figure 2
<p>Stainless steel battery pack concept and typical constituting elements.</p> "> Figure 3
<p>Examples of battery pack from Tesla Model Y-implemented solutions: (<b>a</b>)—exploded view of the battery pack; (<b>b</b>)—exploded view of the lower enclosures; (<b>c</b>)—the numbered red arrows show the fasteners locations [<a href="#B29-vehicles-05-00028" class="html-bibr">29</a>].</p> "> Figure 4
<p>Comparison of the battery packs of VW MQB platform (<b>left</b>) and VW MEB platform (<b>right</b>).</p> "> Figure 5
<p>The solution patented by Tesla for the integration of the battery pack to the underbody structure [<a href="#B30-vehicles-05-00028" class="html-bibr">30</a>].</p> "> Figure 6
<p>Example of two dedicated BEV skateboard architectures from Hyundai (<b>a</b>) and Ford (<b>b</b>) [<a href="#B29-vehicles-05-00028" class="html-bibr">29</a>].</p> "> Figure 7
<p>The cross-section of the Tesla Model Y rocker with multi-cell reinforcement inside (<b>a</b>) and the left side body assembly (<b>b</b>) [<a href="#B29-vehicles-05-00028" class="html-bibr">29</a>].</p> "> Figure 8
<p>Jaguar I-pace underbody and main structural features of the BEV platform [<a href="#B29-vehicles-05-00028" class="html-bibr">29</a>].</p> "> Figure 9
<p>Five different solution: multi-cell-extruded inserts (<b>A</b>–<b>C</b>) and stamped sheet-reinforcing structures (<b>D</b>,<b>E</b>) implemented in BEVs to increment the side energy-absorption capability [<a href="#B29-vehicles-05-00028" class="html-bibr">29</a>].</p> "> Figure 10
<p>Constitutive elements of the Audi e-tron battery pack [<a href="#B31-vehicles-05-00028" class="html-bibr">31</a>].</p> "> Figure 11
<p>(<b>a</b>) Simplified generic model of the underbody for a low segment BEV. (<b>b</b>) The exploded view of the underbody model.</p> "> Figure 12
<p>FE results of the pole side impact on the simplified underbody model: energy absorbed by the battery case (<b>a</b>), and lateral loads on the floor and battery case (<b>b</b>).</p> "> Figure 13
<p>FE results of the pole side impact on the simplified underbody model: side deformation of the rocker (<b>a</b>), and force transmitted to the battery case (<b>b</b>).</p> "> Figure 14
<p>Maximum rotation angle along the longitudinal axis of the same vehicle (KIA Soul) equipped with different powertrain configurations (ICEV and BEV) evaluated during the pole side impact.</p> ">
Abstract
:1. Introduction
2. BEV Architecture and Main Structural Design Solutions
2.1. Underbody Functions
- The structural function: static and dynamic strengths and stiffnesses are of crucial importance for the dynamic and NVH performance of the vehicle;
- The safety function: the underbody must contribute on the one hand to appropriate protection for the occupants, as it is an essential part of the passenger compartment, and more generally to distribute the energy absorption during impact (both frontal and lateral) events, and on the other hand, in the specific case of BEVs, to appropriate protection of the battery pack to avoid fire or explosion hazards of this component [26].
2.2. Battery System Technology
2.3. Battery Pack Enclosure
- Structural stability: The battery pack must be designed to support the cells without affecting their operability, to be properly linked to the underbody to sustain the relevant mass of the battery cells during static and dynamic loading and granting adequate NVH performance.
- Placement: The battery pack should be placed as close as possible to the ground, to lower the center of gravity of the vehicle and thus not affect its dynamic riding performances. The battery placement is also crucial to determine the vehicle packaging and the vehicle’s occupant ergonomics.
- Improvement in underbody stiffness: In the design of new HEV and BEV bodies, the battery pack is expected to contribute to the underbody structural stiffness by coupling with it to constitute a sort of sandwich structure.
- Crash protection: The battery pack must be placed and protected through adequate crash absorption structures; no battery case deformation is acceptable to avoid cell damages and possible fire or explosion due to cell breakage.
- Thermal management: The battery cells need to be maintained in the optimal operating temperature range between 25 °C and 35 °C, either by heating or cooling. This is of capital importance in order to reduce the ageing effects and to achieve the longest operative life.
- Protection from external environment: The battery pack must provide adequate protection from road debris and punctures to avoid damages to the cells. Adequate ground clearance and pack shielding are necessary.
2.4. Battery Pack Location and Integration
2.5. Design Solutions for Crashworthiness and Battery Protection
3. Approaches in the Crashworthiness Design
4. Conclusions
Author Contributions
Funding
Conflicts of Interest
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Belingardi, G.; Scattina, A. Battery Pack and Underbody: Integration in the Structure Design for Battery Electric Vehicles—Challenges and Solutions. Vehicles 2023, 5, 498-514. https://doi.org/10.3390/vehicles5020028
Belingardi G, Scattina A. Battery Pack and Underbody: Integration in the Structure Design for Battery Electric Vehicles—Challenges and Solutions. Vehicles. 2023; 5(2):498-514. https://doi.org/10.3390/vehicles5020028
Chicago/Turabian StyleBelingardi, Giovanni, and Alessandro Scattina. 2023. "Battery Pack and Underbody: Integration in the Structure Design for Battery Electric Vehicles—Challenges and Solutions" Vehicles 5, no. 2: 498-514. https://doi.org/10.3390/vehicles5020028