Multi‐objective optimization of lithium‐ion battery pack casing for electric vehicles: Key role of materials design and their influence

International Journal of Energy ResearchVolume 44, Issue 12 p. 9414-9437 SPECIAL ISSUE RESEARCH ARTICLE Multi-objective optimization of lithium-ion battery pack casing for electric vehicles: Key role of materials design and their influence Yihui Zhang, Yihui Zhang orcid.org/0000-0003-0821-4014 Intelligent Manufacturing Key Laboratory of Ministry of Education, Shantou University, Guangdong, China Shantou Ruixiang Mould Co Ltd, Shantou, ChinaSearch for more papers by this authorSiqi Chen, Siqi Chen Intelligent Manufacturing Key Laboratory of Ministry of Education, Shantou University, Guangdong, ChinaSearch for more papers by this authorM.E. Shahin, M.E. Shahin Department of Mechanical, Materials and Manufacturing Engineering, University of Nottingham Malaysia Campus, Semenyih, MalaysiaSearch for more papers by this authorXiaodong Niu, Corresponding Author Xiaodong Niu xdniu@stu.edu.cn Intelligent Manufacturing Key Laboratory of Ministry of Education, Shantou University, Guangdong, China Shantou Ruixiang Mould Co Ltd, Shantou, China Correspondence Xiaodong Niu, Intelligent Manufacturing Key Laboratory of Ministry of Education, Shantou University, Guangdong, China. Email: xdniu@stu.edu.cnSearch for more papers by this authorLiang Gao, Liang Gao orcid.org/0000-0002-1485-0722 State Key Lab of Digital Manufacturing Equipment and Technology, School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan, ChinaSearch for more papers by this authorC.M.M. Chin, C.M.M. Chin Department of Mechanical, Materials and Manufacturing Engineering, University of Nottingham Malaysia Campus, Semenyih, MalaysiaSearch for more papers by this authorNengsheng Bao, Nengsheng Bao Intelligent Manufacturing Key Laboratory of Ministry of Education, Shantou University, Guangdong, ChinaSearch for more papers by this authorChin-Tsan Wang, Chin-Tsan Wang orcid.org/0000-0003-0989-076X Department of Mechanical and Electro-Mechanical Engineering, National Ilan University, Yilan City, TaiwanSearch for more papers by this authorAkhil Garg, Akhil Garg orcid.org/0000-0001-5731-4105 State Key Lab of Digital Manufacturing Equipment and Technology, School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan, ChinaSearch for more papers by this authorAnkit Goyal, Ankit Goyal orcid.org/0000-0001-7696-2327 Institute of Physics, University of Amsterdam, Amsterdam, The NetherlandsSearch for more papers by this author Yihui Zhang, Yihui Zhang orcid.org/0000-0003-0821-4014 Intelligent Manufacturing Key Laboratory of Ministry of Education, Shantou University, Guangdong, China Shantou Ruixiang Mould Co Ltd, Shantou, ChinaSearch for more papers by this authorSiqi Chen, Siqi Chen Intelligent Manufacturing Key Laboratory of Ministry of Education, Shantou University, Guangdong, ChinaSearch for more papers by this authorM.E. Shahin, M.E. Shahin Department of Mechanical, Materials and Manufacturing Engineering, University of Nottingham Malaysia Campus, Semenyih, MalaysiaSearch for more papers by this authorXiaodong Niu, Corresponding Author Xiaodong Niu xdniu@stu.edu.cn Intelligent Manufacturing Key Laboratory of Ministry of Education, Shantou University, Guangdong, China Shantou Ruixiang Mould Co Ltd, Shantou, China Correspondence Xiaodong Niu, Intelligent Manufacturing Key Laboratory of Ministry of Education, Shantou University, Guangdong, China. Email: xdniu@stu.edu.cnSearch for more papers by this authorLiang Gao, Liang Gao orcid.org/0000-0002-1485-0722 State Key Lab of Digital Manufacturing Equipment and Technology, School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan, ChinaSearch for more papers by this authorC.M.M. Chin, C.M.M. Chin Department of Mechanical, Materials and Manufacturing Engineering, University of Nottingham Malaysia Campus, Semenyih, MalaysiaSearch for more papers by this authorNengsheng Bao, Nengsheng Bao Intelligent Manufacturing Key Laboratory of Ministry of Education, Shantou University, Guangdong, ChinaSearch for more papers by this authorChin-Tsan Wang, Chin-Tsan Wang orcid.org/0000-0003-0989-076X Department of Mechanical and Electro-Mechanical Engineering, National Ilan University, Yilan City, TaiwanSearch for more papers by this authorAkhil Garg, Akhil Garg orcid.org/0000-0001-5731-4105 State Key Lab of Digital Manufacturing Equipment and Technology, School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan, ChinaSearch for more papers by this authorAnkit Goyal, Ankit Goyal orcid.org/0000-0001-7696-2327 Institute of Physics, University of Amsterdam, Amsterdam, The NetherlandsSearch for more papers by this author First published: 01 November 2019 https://doi.org/10.1002/er.4965Citations: 4Read the full textAboutPDF ToolsRequest permissionExport citationAdd to favoritesTrack citation ShareShare Give accessShare full text accessShare full-text accessPlease review our Terms and Conditions of Use and check box below to share full-text version of article.I have read and accept the Wiley Online Library Terms and Conditions of UseShareable LinkUse the link below to share a full-text version of this article with your friends and colleagues. Learn more.Copy URL Share a linkShare onFacebookTwitterLinkedInRedditWechat Summary The battery box is the structure that comprises the battery cells and its casing. It is designed to fix and protect the battery module. During the actual driving, there exists stress and resonance on a battery pack and its outer casing due to external vibration and shock. The safety of an electric vehicle largely depends on the mechanical characteristics of its battery pack. Besides, a lighter weight electric vehicle has a longer driving range, which makes it much more popular in vehicle market. In this paper, a comprehensive design procedure based on multi-objective optimization and experiments is applied to compare the maximum equivalent stress and resonance frequency on a battery pack casing with different materials (DC01 steel, aluminum 6061, copper C22000, and carbon nanotube [CNT]) under bumpy road, sharp turns, and sudden braking conditions to obtain the best material. Moreover, CNT is proved to be the best material considering all the performance standards. Response surface optimization design method is adopted to get an optimal design of the battery pack casing. Optimization results conclude that the maximum equivalent stress can be reduced from 3.9243 to 3.2363 MPa, and the six-order resonance frequency can be increased from 722.65 to 788.71 Hz. Experiments are carried to validate the mechanical performance of the optimal design; the deviation between the simulation and experimental results is within the tolerance. Citing Literature Volume44, Issue12Special Issue: Sustainable Energy and Green Technologies10 October 2020Pages 9414-9437 RelatedInformation