Multi-objective optimization of lithium-ion battery pack casing for electric vehicles: Key role of materials design and their influence
Yihui Zhang
Intelligent Manufacturing Key Laboratory of Ministry of Education, Shantou University, Guangdong, China
Shantou Ruixiang Mould Co Ltd, Shantou, China
Search for more papers by this authorSiqi Chen
Intelligent Manufacturing Key Laboratory of Ministry of Education, Shantou University, Guangdong, China
Search for more papers by this authorM.E. Shahin
Department of Mechanical, Materials and Manufacturing Engineering, University of Nottingham Malaysia Campus, Semenyih, Malaysia
Search for more papers by this authorCorresponding Author
Xiaodong Niu
Intelligent Manufacturing Key Laboratory of Ministry of Education, Shantou University, Guangdong, China
Shantou Ruixiang Mould Co Ltd, Shantou, China
Correspondence
Xiaodong Niu, Intelligent Manufacturing Key Laboratory of Ministry of Education, Shantou University, Guangdong, China.
Email: [email protected]
Search for more papers by this authorLiang Gao
State Key Lab of Digital Manufacturing Equipment and Technology, School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan, China
Search for more papers by this authorC.M.M. Chin
Department of Mechanical, Materials and Manufacturing Engineering, University of Nottingham Malaysia Campus, Semenyih, Malaysia
Search for more papers by this authorNengsheng Bao
Intelligent Manufacturing Key Laboratory of Ministry of Education, Shantou University, Guangdong, China
Search for more papers by this authorChin-Tsan Wang
Department of Mechanical and Electro-Mechanical Engineering, National Ilan University, Yilan City, Taiwan
Search for more papers by this authorAkhil Garg
State Key Lab of Digital Manufacturing Equipment and Technology, School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan, China
Search for more papers by this authorAnkit Goyal
Institute of Physics, University of Amsterdam, Amsterdam, The Netherlands
Search for more papers by this authorYihui Zhang
Intelligent Manufacturing Key Laboratory of Ministry of Education, Shantou University, Guangdong, China
Shantou Ruixiang Mould Co Ltd, Shantou, China
Search for more papers by this authorSiqi Chen
Intelligent Manufacturing Key Laboratory of Ministry of Education, Shantou University, Guangdong, China
Search for more papers by this authorM.E. Shahin
Department of Mechanical, Materials and Manufacturing Engineering, University of Nottingham Malaysia Campus, Semenyih, Malaysia
Search for more papers by this authorCorresponding Author
Xiaodong Niu
Intelligent Manufacturing Key Laboratory of Ministry of Education, Shantou University, Guangdong, China
Shantou Ruixiang Mould Co Ltd, Shantou, China
Correspondence
Xiaodong Niu, Intelligent Manufacturing Key Laboratory of Ministry of Education, Shantou University, Guangdong, China.
Email: [email protected]
Search for more papers by this authorLiang Gao
State Key Lab of Digital Manufacturing Equipment and Technology, School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan, China
Search for more papers by this authorC.M.M. Chin
Department of Mechanical, Materials and Manufacturing Engineering, University of Nottingham Malaysia Campus, Semenyih, Malaysia
Search for more papers by this authorNengsheng Bao
Intelligent Manufacturing Key Laboratory of Ministry of Education, Shantou University, Guangdong, China
Search for more papers by this authorChin-Tsan Wang
Department of Mechanical and Electro-Mechanical Engineering, National Ilan University, Yilan City, Taiwan
Search for more papers by this authorAkhil Garg
State Key Lab of Digital Manufacturing Equipment and Technology, School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan, China
Search for more papers by this authorAnkit Goyal
Institute of Physics, University of Amsterdam, Amsterdam, The Netherlands
Search for more papers by this authorSummary
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.
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