Development of a Mechanical Vehicle Battery Module Simulation Model Combined with Short Circuit Detection

In recent years, electric vehicles (EVs) have gained significant traction within the automotive industry, driven by the societal push towards climate neutrality. These vehicles predominantly utilize lithium-ion batteries (LIBs) for storing electric traction energy, posing new challenges in crash safety. This paper presents the development of a mechanically validated LIB module simulation model specifically for crash applications, augmented with virtual short circuit detection. A pouch cell simulation model is created and validated using mechanical test data from two distinct out-of-plane load cases. Additionally, a method for virtual short circuit prediction is devised and successfully demonstrated. The model is then extended to the battery module level. Full-scale mechanical testing of the battery modules is performed, and the simulation data are compared with the empirical data, demonstrating the model’s validity in the out-of-plane direction. Key metrics such as force-displacement characteristics, force, deformation, and displacement during short circuit events are accurately replicated. It is the first mechanically valid model of a LIB pouch cell module incorporating short circuit prediction with hot spot location, that can be used in full vehicle crash simulations for EVs. The upscaling to full vehicle simulation is enabled by a macro-mechanical simulation approach which creates a computationally efficient model.