Analyzing EV Battery Package Responses during Side Pole Impacts with Multiple Speeds and Locations

<div class="section abstract"><div class="htmlview paragraph">Electric vehicles (EVs) have experienced significant growth, and the battery safety of EVs has drawn increased attention. However, the mechanical responses of battery during crashes have rarely been studied. Hence, the objective of this study was to understand EV battery package mechanics during side-pole crashes at different impact locations and speeds beyond regulated side-pole test with one specific speed and one location. An EV finite element (FE) model with a battery package was used. Side-pole impact simulations were conducted at four impact locations, including the baseline impact location according to side-pole impact regulation, plus three positions by moving the rigid pole 400 mm toward the back of the EV and moving the pole 400 and 800 mm toward the front of the EV. In addition, the impact velocities at 32, 50, and 80 km/h were simulated. Based on simulations, the peak relative displacement, the maximum change in gap between batteries, the maximum change in gap between the battery and the inner wall, and battery housing stress were analyzed. Lastly, frontal impacts at both 50 and 80 km/h were simulated for comparison. Results demonstrated that at 50 km/h side-pole impact, the battery was left intact. However, at 80 km/h, a slight intrusion of deformed battery housing into the battery was observed. Impact locations played a critical role, as the impacts near the center of the battery package induced the largest deformations. In comparison, during all frontal impacts, the battery was not affected. Overall, side-pole impacts at higher velocities beyond regulated speed could be further investigated for continuously enhancing EV safety.</div></div>