FEV has developed a mixed simulation and testing course of for the optimization of thermal propagation conduct in automotive battery packs. The corporate claims the method may also help to cut back the chance of harm and injury from battery cell thermal runaway, whereas additionally saving growth time and price.
Thermal runaway is a key security side for hybrid and electrical autos. The primary thermal propagation regulation is predicted in January 2021. The GB/T 38031 customary in China would require that car passengers be warned at the very least 5 minutes earlier than a fireplace from a thermal occasion extends past the battery pack, or battery venting gasoline enters the cabin. Different markets and regulatory our bodies are anticipated to observe.
“FEV’s simulation-based method to optimize for battery thermal propagation is paired with our design, growth and testing capabilities at our world-class eDLP facility,” mentioned CEO Stefan Pischinger. “This uniquely positions FEV to help your complete thermal propagation growth course of.”
The simulation-based method begins after key CAD dimensions and pack geometries are outlined within the base growth part. FEV has created two customizable fashions for this objective. Multiphysics simulation produces a mannequin to judge and optimize thermal runaway of 1 cell and propagation between battery cells, in addition to between battery modules. This mannequin and its customization for particular buyer necessities permit for design optimization and introduction of countermeasures akin to warmth obstacles. In parallel, a second, fluid-based venting gasoline mannequin is personalized, which is used to evaluate and optimize the design of the venting paths, dimensioning of venting valves in addition to the indication of crucial busbar routing contained in the battery pack.
The thermal and venting gasoline fashions are developed after which personalized individually. Every mannequin is validated additional utilizing bodily check information. This testing method is predicated on a step-by-step validation of cell to module to pack, whereas on the pack stage, completely different dummy packs are used to judge thermal propagation conduct. The cascaded testing method may be optimized if any information (e.g. cell information) are already obtainable. Experimental information may be collected early in growth, with out constructing a completely purposeful battery pack.
After the fashions are validated with bodily check information, they’re mixed right into a complete coupled mannequin, containing the thermal battery mannequin in addition to native warmth switch coefficients and fluid/gasoline temperatures from the venting gasoline mannequin. Lastly, the design is examined and validated as an entire battery pack.