Automotive Engineering - December 2022 - BET14

Cell Design
novel cathode and anode materials.
Realistic and predictive virtual
testing
must tackle material modeling problems
at the atomistic, molecular, cell, and module/pack
level, as well as integrate the
physics and chemistry models at all scales.
As new materials and alloy compositions
are developed, research must move
to the level of active material modeling.
With multiphysics and multiscale simulation
technology, mechanical, thermal, diffusion
and electrical behavior of the battery
cell 3D design can be analyzed and improved.
Unified design and MODSIM applications
enable engineers to understand
the potential forces of the materials acting
on the cell geometry, as well as the performance,
aging, and safety characteristics of
the battery. A unique advancement in multiphysics
and multiscale simulation technology
enables the analysis of the coupled
behavior of thermoelectrochemistry with
swelling in batteries. This type of coupled
simulation has the potential to help ensure
battery safety, optimize performance,
and improve the driving range for EVs.
The development progression continues
with design and engineering of the
battery module and pack configuration.
During this stage, it is critical that design
and engineering teams collaborate on
structural integrity, safety, and thermal
management.
Multiphysics simulation
can be used to analyze the thermoelectric
performance of the module and pack, just
as in the battery cell itself.
Structural analysis helps analyze the
battery module for crush, drop, shock, and
penetration, which can be time-consuming,
wasteful, and dangerous with physical
testing. Alternative designs for module
and pack configurations and cooling
options
can be analyzed virtually to
achieve the required thermal characteristics
for arbitrary charge and discharge
cycles
in various ambient conditions.
Traditional physical testing can take several
months. Virtual testing with unified
design and simulation technologies can
significantly reduce the time to make reliable
performance decisions.
Concurrently, with the virtual developFull
vehicle dynamic simulations, with real-time software, hardware- and driver-in-the-loop
enables the evaluation of EV performance in a wide range of vehicle operating conditions.
(Image: Dassault Systèmes)
ment of the battery, designers and engineers
can collaborate on integrating the
battery module and pack within the virtual
twin of the full vehicle. This includes the
battery management system (BMS), the
" brain " of the EV battery pack. With traditional
development tools and methods,
performance gains created at previous
stages can be stifled by the limitations of
On the left is a 3D Parametric model of a battery cell. Using the same model, a range of simulations can be performed to evaluate stress, thermal,
electro-chemical performance, cyclic swelling, and more. The image on the right is a Finite Element Analysis of charging-induced stresses
in the jellyroll of 3D Battery design. (Image: Dassault Systèmes)
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Battery & Electrification Technology, December 2022

Automotive Engineering - December 2022

Table of Contents for the Digital Edition of Automotive Engineering - December 2022