Enhancing crashworthiness performance of a battery pack system using multicell square tube structures

This paper focuses on the mechanical reliability and crashworthiness performance of battery pack systems in electric vehicles, evaluating multicell square tube crash wall structures to enhance safety during side pole collisions. We used a nonlinear finite element model to simulate a variety of impact configurations and velocities. The effectiveness of two battery pack layouts was compared: the baseline without a crash wall and the modified layout with a crash wall consisting of five multicell tube structures. The results indicated that the crash wall structures significantly improved performance over the baseline layout. This design reduces the intrusion of the bottom shell by over 45% in the critical impact zone. A hybrid Multi-Criteria Decision Making (MCDM) framework combined Complex Proportional Assessment (COPRAS) and PROMETHEE: Preference Ranking Organization Method for Enrichment of Evaluations effectively utilizes a simulation environment, such as Monte-Carlo simulation to generate a set of ranks to choose the optimum design. Specifically, the corner-to-web (C2W1) structure demonstrated a balanced performance in terms of specific energy absorption , peak load, crushing load efficiency, and minimization of battery pack intrusion. These advancements emphasize the importance of using optimized crash wall structures to enhance battery pack systems’ safety, structural reliability, and integrity. • Multicell square tube structures are integrated into a battery pack for crashworthiness. • The effects of 5 multicell tube structures on crashworthiness are analyzed. • An optimal structure is derived using a hybrid MCDM framework with Monte Carlo. • Crash wall structures improve performance, reducing bottom shell intrusion by 45%.