Safety challenges in high-voltage electric vehicle collisions: risks and design strategies

The rapid advancement of electric vehicles (EVs) has introduced new structural safety challenges, especially in side-impact scenarios due to the presence of high-voltage battery packs. This study investigates the structural performance of a Battery Electric Vehicle (BEV) under a lateral pole crash scenario using Finite Element Analysis (FEA). A detailed BIW (Body-in-White) model was developed using Hyper Mesh and subjected to a side pole impact simulation to evaluate intrusion, deformation behavior, and plastic strain distribution in the battery casing. Material selection for various BIW components and battery housing was optimized for strength and weight efficiency. The results indicate a maximum intrusion of 143.25 mm in the battery compartment and significant strain localization near the B-pillar. Comparative analysis with baseline (non-battery) models shows increased deformation and altered velocity profiles at the center of gravity due to the added mass of the battery pack. While simulation results align with known vehicle deformation patterns (Honda Accord), a more conservative interpretation is advised in the absence of experimental crash validation. Recommendations are made for improved crashworthiness through structural reinforcement and refined material application.