Analyzing EV Battery Package Responses during Side Pole Impacts with Multiple Speeds and Locations

Electric vehicles (EV) have experienced significant growth recently. Battery safety of EV has drawn increased attention. However, battery mechanical responses due to crash have rarely been studied. Hence, the objective of this study was to understand EV battery package mechanics during side pole crashes with different impact locations and speeds. A full EV finite element (FE) model with detailed battery package was used. Eight side pole impact simulations were conducted to study four impact locations, including the baseline impact location according to side-pole impact regulation, plus three positions by moving the rigid pole 400 mm toward the back of EV, and moving the pole 400 and 800mm toward the front of the EV. Different from 32 km/h impact velocity as specified in regulations, two higher impact speeds of 50 km/h and 80 km/h were applied. The relative displacement, change of the gap between the battery and the inner wall, and battery peak stress were analyzed. In addition, frontal impacts at both 50 and 80 km/h were simulated for comparison. Results demonstrated that at 50 km/h the battery was left intact. However, at 80 km/h, slight intrusion into the battery was observed. Also, impact locations played a critical role as impact near the center of the bottom battery package induced the largest deformation. During frontal impacts, the battery was not affected. Overall, side pole impact at higher velocities beyond regulated speed could be further investigated for further enhancing EV safety.