Fatigue damage spectrum-based assessment of vibration standards on Battery Pack for EV’s using stress as a response metric

Estimation of vibration severity on battery packs designed for Electric Vehicle by calculating fatigue damage spectrum for different global standards and actual vibrations in field. Review investigates factors influencing the vibration durability of HV batteries and components. The research objective of providing the underpinning knowledge that allows manufacturers to improve the mechanical durability and performance of EV battery assemblies with respect to vibration. Vibration fatigue methods uses stress as the response metric of interest, which requires Stress vs. Numbers of failure free Cycles (S-N) curve as input material property. From this "b" Basquin coefficient is evaluated for common material used for battery pack design. The damage index is plotted as a function of natural frequency, with separate curves for each Q and b pairs leads to different FDS for Global available standards ISO-12405, ISO-16750, ECE-R100 and AIS-048 etc. Fatigue damage spectrum is useful for comparing the relative damage potential between profiles. Comparison of FDS for current EV vibration test standards which apply vibration via a Swept Sine Profile and Random Profile are compared with 100,000 Miles of BEV Durability. This research also defines innovative testing techniques and characterization data, which can be employed by engineers to predict the warranty performance, of future EV battery assemblies.