CN111222269A - CAE-based simulation test method for mechanical impact process of battery pack - Google Patents
CAE-based simulation test method for mechanical impact process of battery pack Download PDFInfo
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- CN111222269A CN111222269A CN201911312952.6A CN201911312952A CN111222269A CN 111222269 A CN111222269 A CN 111222269A CN 201911312952 A CN201911312952 A CN 201911312952A CN 111222269 A CN111222269 A CN 111222269A
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Abstract
The invention relates to the technical field of battery testing, in particular to a simulation testing method for a mechanical impact process of a battery pack based on CAE, which comprises the following steps: constructing a finite element model of a battery pack, and setting parameters of the finite element model according to the condition of the battery pack; setting a contact boundary condition, and applying a load; and explicitly solving the speed, the acceleration and the displacement of the finite element model, and calculating the stress and equivalent plastic strain conditions of each part of the finite element model at different time so as to judge whether each part meets the requirement of impact calculation. The finite element method is applied to analysis of the battery pack impact process, the dependence of the traditional impact test method on samples is overcome, the sample preparation times of the battery pack samples in the research and development process are reduced, the requirements on hardware research and development are reduced, the design defects can be quickly found in the design process, the design is optimized, the test times are reduced, and the design cost is reduced.
Description
Technical Field
The invention relates to the technical field of battery testing, in particular to a simulation testing method for a mechanical impact process of a battery pack based on CAE.
Background
In recent years, the development of new energy automobiles around the world has formed a consensus, and in the new energy automobiles, a battery pack is a main carrier of the new energy automobiles, and mainly functions to provide a mounting structure for each system element inside the battery pack and protect each component. The battery pack has enough structural stability, which is a prerequisite for ensuring the normal work of the battery pack, and the damage of the structure can influence the reserve electric quantity and the service life of the battery pack.
The battery pack impact test is one of common modes for detecting the structural stability of the battery pack, a battery pack sample is impacted three times in the Z-axis direction by a half-sine impact wave of 25g and 15ms, and whether a product is qualified or not is judged by checking whether the phenomena of electrolyte leakage, ignition or explosion and the like exist. Since the impact test can be performed only after the battery pack sample is manufactured, the sample preparation is repeated during the whole product development cycle, which consumes a lot of manpower, material resources and time. And the impact test can only obtain the result after sudden mechanical impact, and can not accurately analyze and obtain the spatial distribution of stress, strain and displacement in the process of mechanical impact, and the change condition and the design defect of the stress, the strain and the displacement along with time so as to obtain a more optimized structural scheme.
Disclosure of Invention
The analysis method of the battery pack impact process based on the CAE simulation technology does not depend on a product sample excessively, the change relation of stress, strain and displacement of any point on the structure of the battery pack in the impact process along with time can be calculated by establishing a battery pack finite element analysis model, and whether the structure of the battery pack is stable or not is judged by analyzing whether the stress and the deformation of the structure are in a reasonable change range or not. In the research and development period, the simulation model is modified to replace repeated sample preparation, so that more resources and time can be saved.
Therefore, the invention provides a simulation test method for a mechanical impact process of a battery pack based on CAE, which comprises the following steps:
constructing a finite element model of a battery pack, and setting parameters of the finite element model according to the condition of the battery pack;
setting a contact boundary condition, and applying a load;
and explicitly solving the speed, the acceleration and the displacement of the finite element model, and calculating the stress and equivalent plastic strain conditions of each part of the finite element model at different time so as to judge whether each part meets the requirement of impact calculation.
In some embodiments, preferably, the constructing the finite element model of the battery pack includes importing the three-dimensional geometric model of the battery pack into finite element analysis software and processing the three-dimensional geometric model of the battery pack;
the processing comprises the following steps:
for parts with smaller mass, neglecting the parts in simulation analysis;
simplifying the structural characteristics of the midpoint, line, surface and angle of the established three-dimensional structure of the battery pack;
performing middle surface extraction treatment on the shell sheet metal part and the internal fixed support, and repairing incomplete and broken surface characteristics in the middle surface;
parts in the built three-dimensional structure, which are not concerned with local stress, but cannot ignore the mass of the parts, are replaced by mass points.
In some embodiments, the parameters preferably include a finite element mesh, a shape of the finite element model, a size of the components, material properties of the components, and a connection relationship of the components.
In some embodiments, the finite element mesh preferably has mesh cells with a size of 2-8 mm;
in the battery pack structure, a grid model of a plate-shell structure mainly adopts quadrilateral units, the percentage of the quadrilateral units is not less than 95%, a grid model of an entity structure adopts hexahedral units, and a non-concerned area adopts tetrahedral units;
local areas where distortion is easily generated in grids near the connecting position and the round hole fillet are subjected to local grid refinement.
In some embodiments, mass amplification is preferably performed at the time of calculation.
In some embodiments, it is preferred that the mass increase in the mass amplification is 5% or less.
In some embodiments, it is preferable to apply acceleration stimuli to simulate a sudden impact during load application, and to apply acceleration loads at the battery pack foot or lug connection to the test stand.
Further, the variation relation of the energy in the impact process is also calculated.
Further, when the result meets the following condition, the part is obtained to meet the requirement of impact calculation:
the maximum stress of the model part is less than the tensile strength of the material;
the maximum equivalent plastic strain of the model part is less than the elongation of the material;
the battery module does not collide with the case cover.
Further, the result does not meet the requirement of impact calculation, one or more parameters of the size, the thickness and the material of the battery pack shell or the internal connecting plate are reset or the structural design is optimized, and the simulation test is carried out again until the requirement of impact calculation is met.
Compared with the prior art, the invention has the following beneficial effects:
the finite element method is applied to analysis of the battery pack impact process, the dependence of the traditional impact test method on samples is overcome, the sample preparation times of the battery pack samples in the research and development process are reduced, the requirements on research and development hardware are reduced, the design defects can be quickly found in the design process, the design is optimized, the test times are reduced, and the design cost is reduced.
Drawings
The above and/or additional aspects and advantages of the present invention will become apparent and readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings of which:
FIG. 1 illustrates a flow diagram relating to CAE simulation according to the present invention;
FIG. 2 shows a schematic diagram of a battery pack impact model according to the present invention;
FIG. 3 shows a half-sinusoidal shock wave of 15ms at 3 times in relation to the present invention;
fig. 4 shows the change of energy with time during impact of a battery pack according to the present invention;
FIG. 5 shows the overall stress cloud at T of 3ms as referred to in example 1 of the present invention;
FIG. 6 shows an overall stress cloud at T of 6ms as referred to in example 1 of the present invention;
FIG. 7 shows an overall stress cloud at T of 9ms as referred to in example 1 of the present invention;
FIG. 8 shows the overall stress cloud at T of 13ms as referred to in example 1 of the present invention;
fig. 9 shows a cloud of extracted maximum stresses involved in embodiment 1 of the present invention;
fig. 10 shows a cloud diagram of extraction of maximum equivalent plastic strain involved in embodiment 1 of the present invention.
Detailed Description
In order that the above objects, features and advantages of the present invention can be more clearly understood, a more particular description of the invention will be rendered by reference to the appended drawings. It should be noted that the embodiments and features of the embodiments of the present application may be combined with each other without conflict.
In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention, however, the present invention may be practiced in other ways than those specifically described herein, and therefore the scope of the present invention is not limited to the specific embodiments disclosed below.
A method for analyzing a mechanical impact process of a battery pack based on a CAE simulation technology is disclosed, as shown in FIG. 1, and specifically comprises the following steps:
(1) three-dimensional structural geometry model import
And importing the three-dimensional geometric model of the battery pack comprising the battery module, various electronic appliances, connecting plates and the support structure into finite element analysis software. For parts with smaller mass, the influence on the overall structure stress and strain of the battery pack is smaller, so that the parts are ignored in simulation analysis, the calculation cost is reduced, and the calculation efficiency is improved.
(2) Finite element model building
Establishing a battery pack finite element model (as shown in fig. 2), and establishing a three-dimensional cartesian coordinate system, so that an X axis of the three-dimensional coordinate system is parallel to the driving direction of an automobile where the battery pack is located, a Y axis is perpendicular to the horizontal direction of the driving direction, and a Z axis is the height direction.
① simplify the handling of some of the structural features (e.g., points, lines, faces, small rounded corners, chamfers, etc.) in the three-dimensional structure of the created battery pack.
② the sheet metal part of the shell and the internal fixed support are processed to repair the incomplete and broken surface characteristics in the middle surface, the solid structure remains the main structure, removes the tiny structure, avoids the local complex grid and increases the computation cost.
③ some parts of the built three-dimensional structure which do not care about local stress but cannot ignore their mass are replaced by mass points to reduce the amount of calculation.
(3) Partitioning finite element mesh model
And establishing a finite element grid model for the battery pack shell, the battery module, various electronic appliances, each connecting plate and the support structure according to the actual structure. The size of the grid unit used by the grid model of the battery pack is 2 mm-8 mm. In the battery pack structure, the grid model of the plate-shell structure mainly adopts quadrilateral units, the percentage of the quadrilateral units is not less than 95%, the grid model of the solid bodies such as electric devices mainly adopts hexahedral units, and the non-concerned area can adopt tetrahedral units. Local area is near like hookup location, near round hole fillet, and the net produces the distortion easily, refines local net, and it is 1/2 of original net size to encrypt the net, when guaranteeing computational efficiency, promotes the computational accuracy as far as possible.
(4) Setting material properties
And setting the size, thickness and material properties of the battery pack shell, the battery module, various electronic appliances, each connecting plate and the support structure according to the actual structure.
(5) Establishing a connection relationship
According to the actual process, the connection relation among the structures is established, and the connection relation comprises spot welding, carbon dioxide protection welding, seam welding, bolt connection, clamping connection and the like. The connection relation has great influence on the accuracy of the calculation result, so that the model processing is carried out according to the actual connection state, and the detailed model structure connection is established for the important force transmission position without simplified processing.
(6) Setting "touch" boundary conditions
The contact relationship may be defined during impact, provided as a general contact relationship, or provided as a "contact pair" at the face where contact occurs during impact to limit the contact boundary constraints between structural members.
(7) Load application
The acceleration excitation is applied to simulate sudden impact, and the Z-direction acceleration load is applied to the connection position of a battery pack support leg or a suspension lug connected with the test bed. For example, the test requires that the impact condition applies a half-sine impact wave of 25g and 15ms, the Z-axis direction impacts three times, as shown in FIG. 3, so that the calculation time can be set to 60ms, the first 45ms is applied with 3 impact excitations, the second 15ms acceleration is set to 0, and the 15ms is left to observe the influence after the impact. The calculation formula of the half-sine shock wave amplitude curve within 15ms of each time of 3 times of shock is as follows:
(8) computational solution
Compared with the traditional implicit solution, the explicit solution has higher efficiency, and because the implicit solution has the problem of convergence difficulty, the complex nonlinear problem with contact is difficult to quickly converge to obtain a calculation result, while the explicit analysis can effectively solve the problem;
explicit solutions are used, which are based on the following theoretical equations: the explicit algorithm adopts a central difference method to perform explicit time integration on the motion equation, and adopts the dynamic condition of one increment step to calculate the dynamic condition of the next increment step. At the beginning of the incremental step, the program solves the dynamic balance equation, i.e., the node mass matrix M times the node acceleration equals the resultant force of the nodes (the difference between the applied external force P and the force I in the cell):
at the start of the incremental step (time t), the acceleration is calculated as:
integration of acceleration over time:
i.e. the velocity and displacement are advanced in time by the acceleration at the start of the incremental step, which satisfies the dynamic equilibrium conditions.
(9) Mass amplification
Although the convergence problem does not exist in the display solution, the calculation time cost is too large, and the operation cost can be reduced under the condition that the loading rate is not required to be artificially increased through quality amplification. Increasing the loading rate may also reduce the computational cost, but is a less desirable method because the strain rate of the material increases in proportion to the loading rate, and artificially increasing the loading rate may artificially change the analysis process when the model parameters change with the strain rate.
Mass amplification is based on the theory as follows: the relationship between the increase in stabilization time and the density of the material is:
However, excessive mass amplification, as well as excessive increase in loading rate, can lead to erroneous results. Therefore, when mass amplification is employed, the mass increase is required to be 5% or less.
(10) Results
Obtaining and processing results through a finite element software system, and carrying out cloud picture processing or graph display on the obtained results, wherein the cloud picture processing or graph display mainly comprises the following steps:
① graph showing the relationship between the change in the overall energy of the model during impact (FIG. 4);
② distribution diagram of stress and displacement on system components in the battery pack at a certain time;
③ equivalent plastic strain profile of system components in a battery pack.
(11) Judging whether the impact calculation meets the requirement
Reading the calculation result, and considering that the part meets the impact calculation requirement when the following conditions are simultaneously met:
① the maximum stress of the model part is less than the tensile strength of its material;
② the maximum equivalent plastic strain of the model part is less than the material elongation of its material;
③ the battery module does not collide with the box cover (as can be seen from the calculated effect diagram);
and (3) if a certain calculated system part does not meet the requirement of impact calculation, resetting one or more parameters of the size, the thickness and the material of the battery pack shell or the internal connecting plate or optimizing the structural design, and repeating the steps (2) to (11).
Example 1
Taking a mechanical impact CAE analysis of the battery pack as an example, the implementation is completed by using Abaqus software, and the steps are as follows:
(1) and importing the three-dimensional geometric model of the battery pack comprising the battery module, various electronic appliances, connecting plates and the support structure into finite element analysis software. For parts with smaller mass, the influence on the overall structure stress and strain of the battery pack is small, and the parts are ignored in simulation analysis.
(2) And establishing a three-dimensional Cartesian coordinate system, so that the X axis of the three-dimensional coordinate system is parallel to the driving direction of the automobile where the battery pack is located, the Y axis is perpendicular to the horizontal direction of the driving direction, and the Z axis is the height direction.
① simplify the handling of some of the structural features (e.g., points, lines, faces, small rounded corners, chamfers, etc.) in the three-dimensional structure of the created battery pack.
② the sheet metal part of the shell and the internal fixed support are processed to repair the incomplete and broken surface characteristics in the middle surface.
③ some parts that do not care about local stresses in the three-dimensional structure being built, but whose mass cannot be ignored, are replaced by mass points.
(3) A finite element grid model of the battery pack is established in finite element software, the unit size adopted by a main body during grid division is 6mm, a metal plate structure is a shell unit, and the battery module and the simplified electric device are body units. The main material is Q235, and the model material property is given according to the actual plate thickness.
(4) And setting connections in the model according to the relation among the actual components, wherein the connections comprise a welding part of the battery pack structure, electrical devices and other bolt connections.
(5) And defining the contact relation during the impact process, and setting the general contact relation of the whole body.
(6) According to the actual test requirement, a half-sine shock wave of 25g and 15ms is applied to the shock working condition, the shock is applied for three times in the Z-axis direction, the calculation time is set to be 60ms, the first 45ms is applied to shock excitation for 3 times, the acceleration of the second 15ms is set to be 0, the influence after the shock is observed in 15ms is left, and the excitation is applied to a support leg fixed with a test bed.
(7) And (3) solving, calculating and extracting a cloud graph of the overall stress changing along with time, as shown in fig. 5-8, in fig. 5, the maximum stress value at 3ms is 123.2MPa, the maximum stress value at 6ms is 217.3MPa, the maximum stress value at 9ms is 306.9MPa, and the maximum stress value at 13ms is 222.9 MPa. The maximum stress value appears at the hangers, and it can be seen that the stress gradually diffuses to the whole from the connection part of the support legs and the shell and the internal limit in 3-13 ms. The stress concentration of the support leg and the local area of the shell is stronger, and the plastic stage is firstly carried out in the partial area.
(8) Taking a battery pack shell as an example, the maximum stress and the maximum equivalent plastic strain of the battery pack shell are extracted, wherein the maximum stress is 236.3MPa as shown in fig. 9, the local area exceeds the yield stress of 235MPa of the material and does not exceed the tensile stress of 370MPa, the maximum equivalent plastic strain is 0.045% as shown in fig. 10, the elongation is lower than 21% of the material, the local yield occurs, and the fracture failure risk is lower.
In practical tests, the battery pack does not have the conditions of fracture deformation and the like in an impact test.
The simulation test method for the mechanical impact process of the CAE-based battery pack provided by the invention has no obvious difference from the actual test.
In the present invention, the terms "first", "second", and "third" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance; the term "plurality" means two or more unless expressly limited otherwise. The terms "mounted," "connected," "fixed," and the like are to be construed broadly, and for example, "connected" may be a fixed connection, a removable connection, or an integral connection; "coupled" may be direct or indirect through an intermediary. The specific meanings of the above terms in the present invention can be understood by those skilled in the art according to specific situations.
In the description of the present invention, it is to be understood that the terms "upper", "lower", "left", "right", "front", "rear", and the like indicate orientations or positional relationships based on those shown in the drawings, and are only for convenience of description and simplification of description, but do not indicate or imply that the referred device or unit must have a specific direction, be constructed in a specific orientation, and be operated, and thus, should not be construed as limiting the present invention.
In the description herein, the description of the terms "one embodiment," "some embodiments," "specific embodiments," etc., means that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, the schematic representations of the terms used above do not necessarily refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.
The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (10)
1. A simulation test method for a mechanical impact process of a battery pack based on CAE is characterized by comprising the following steps:
constructing a finite element model of a battery pack, and setting parameters of the finite element model according to the condition of the battery pack;
setting a contact boundary condition, and applying a load;
and explicitly solving the speed, the acceleration and the displacement of the finite element model, and calculating the stress and equivalent plastic strain conditions of each part of the finite element model at different time so as to judge whether each part meets the requirement of impact calculation.
2. The CAE-based battery pack mechanical shock process simulation test method of claim 1, wherein the constructing the finite element model of the battery pack comprises importing a three-dimensional geometric model of the battery pack into finite element analysis software and processing the three-dimensional geometric model;
the processing comprises the following steps:
for parts with smaller mass, neglecting the parts in simulation analysis;
simplifying the structural characteristics of the midpoint, line, surface and angle of the established three-dimensional structure of the battery pack;
performing middle surface extraction treatment on the shell sheet metal part and the internal fixed support, and repairing incomplete and broken surface characteristics in the middle surface;
parts in the built three-dimensional structure, which are not concerned with local stress, but cannot ignore the mass of the parts, are replaced by mass points.
3. The CAE-based battery pack mechanical shock process simulation test method of claim 1, wherein the parameters include finite element mesh, finite element model shape, dimensions of components, material properties of components and connection relationships of components.
4. The CAE-based battery pack mechanical shock process simulation test method of claim 3, wherein the grid cells used by the finite element grid are 2-8mm in size;
in the battery pack structure, a grid model of a plate-shell structure mainly adopts quadrilateral units, the percentage of the quadrilateral units is not less than 95%, a grid model of an entity structure adopts hexahedral units, and a non-concerned area adopts tetrahedral units;
local areas where distortion is easily generated in grids near the connecting position and the round hole fillet are subjected to local grid refinement.
5. The CAE-based battery pack mechanical shock process simulation test method of claim 1, wherein mass amplification is performed at the time of calculation.
6. The CAE-based battery pack mechanical shock process simulation test method of claim 5, wherein the mass increase is less than or equal to 5% in the mass amplification.
7. The CAE-based battery pack mechanical shock process simulation test method according to claim 1, wherein in the process of load application, acceleration excitation is applied to simulate sudden shock, and acceleration load is applied to a battery pack leg or lug connection part connected with a test bed.
8. The CAE-based battery pack mechanical shock process simulation test method of claim 1, further calculating the variation relationship of energy during shock.
9. The CAE-based battery pack mechanical shock process simulation test method according to any one of claims 1-8, wherein the component is obtained to meet shock calculation requirements when the following conditions are met:
the maximum stress of the model part is less than the tensile strength of the material;
the maximum equivalent plastic strain of the model part is less than the elongation of the material;
the battery module does not collide with the case cover.
10. The CAE-based battery pack mechanical shock procedure simulation test method of claim 9, wherein the results do not satisfy the shock calculation requirements, one or more parameters of the size, thickness, material of the battery pack case or the internal connection plate are re-set or the structural design is optimized, and the simulation test is re-performed until the shock calculation requirements are satisfied.
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