A Fatigue Damage Spectrum-Based Approach to Vibration Durability Test for Vehicle Batteries

For the vibration durability bench test of commercial vehicle batteries, it is essential to have accurate test specifications that exhibit high robustness and reasonable acceleration characteristics. This study evaluates the impact of different battery frame systems on the vibration response of the battery body, as determined by road load spectrum test results of a commercial vehicle battery system. It also confirms the variations in the external environmental load. Utilizing the response spectrum theory, a comprehensive calculation method for the fatigue damage spectrum (FDS) of batteries is developed. The time domain direct accumulation method, frequency domain direct accumulation method, and frequency domain envelope accumulation method are all compared. Analysis of kurtosis and skewness reveals that when the load follows the super-Gaussian distribution characteristics, the time domain direct accumulation method should be used to calculate the fatigue damage spectrum to minimize damage loss rates. The study also examines European standards, Chinese standards, and the working conditions of proving ground, confirming significant differences in the fatigue damage spectrum. By synthesizing working conditions and accelerated test methods, a bench vibration durability test method that meets the requirements of environmental working conditions in China and Europe is established, with an acceleration coefficient of 17.0. This study provides a new guideline for the development of vehicle battery systems.