Material Selection and Assessment of Electric Two-wheeler Battery Enclosure: Structural Study

Recently, Electric Two-Wheelers ETW are changing the face of the global automotive market. This study focused on selecting proper material and mechanical isolation gap to design a protective enclosure for the battery pack of ETW. The integration of the Failure, Modes, Mechanism and Effect Analysis (FMMEA) method is utilized to develop the interface matrix and the severity index of different components of the enclosure. By analyzing different forces from the road conditions, dynamics during turn, acceleration, and deceleration with the enclosure, it becomes a crucial load-bearing element. Employing Finite Element Modeling (FEM), structural strength using materials like AL6061, Q235, C22000, DC 01 and Teflon are assessed under varying static, dynamic and thermal conditions. Modal analysis is conducted to observe the excitation frequencies where the maximum deformation for the metal enclosure is observed beyond 500Hz. AL6061 material that can withstand the stresses and deformations that are under allowable stress limits with negligible deformation is most preferable material based on the results. Minimal of 2.5 mm gap to be provided in case of metal casing and 10mm in case of Teflon is proven.