Simulation of Crush Behavior and Energy Absorption of Vehicle Li-Ion Battery Module with Prismatic Cells

Lithium-ion batteries serve as the main power source for contemporary electric vehicles. Safeguarding these batteries against damage is paramount, as it can trigger accelerated performance deterioration, potential fire hazards, environmental threats, and more. This study explores damage progression of a commercial vehicle lithium-ion battery module containing prismatic cells under indentation crush loading. We employed computational simulations of mechanical loading tests to investigate this behavior. Physical tests involved subjecting modules to low-speed (0.05 m/s) indentations using a V-shaped stainless-steel wedge, under six unique loading conditions. During the tests, force, and voltage change with wedge displacement were monitored. Utilizing experimental insights, we constructed a finite element model, which included key components of the battery module, such as the prismatic cells, steel frames, and various plastic parts. The finite element model reproduced failure modes observed in the tests, and force-displacement responses, closely. Using this model, we further analyzed energy absorption contributions from battery cells and the stainless steel frame. The findings of this work can help better understand the failure mechanisms of typical vehicle module subject to abuse conditions. Furthermore, they provide valuable guidance for enhancing the safety design of battery systems within electric vehicles, ultimately advancing the reliability and security of electric vehicle technology.