Detailed FE Modeling of battery pack to predict Thermal Runaway

Electrified powertrain is the essential need to meet the C02 and NOX emissions compliance. Thereby focus of automotive industry is shifting towards to Electric Vehicle (EV). Thermal Runaway (TR) is still a big challenge to the safety of the EV. The major cause of TR is internal short-circuit of batteries under external mechanical abuse. When Anode and cathode of the battery comes in contact and short circuit happens. Internal short circuit is causing high amount of current flow and energy generation which leads to high increase in temperature. The approach that is used till date by OEMs is to protect the battery pack from structural damage during crash resulting into overdesigning of the vehicle. In this paper, detailed FE modeling of the battery system is considered for evaluating internal short circuit and TR. Solid Randle circuit is used for Multiphysics coupling simulation in Ls-dyna. Solid Randle circuits solves this Multiphysics and derives these electrical and thermal parameters which makes this methodology simple and effective. By integrating thermal, electrical, and mechanical behaviors within a comprehensive simulation framework, we aim to accurately predict the onset and progression of TR during crash event. The approach is to analyze the electrical & thermal parameters on the cell level and then adapt the same modeling methodology to battery module and battery pack level which is further used for full vehicle study. The results provide insights into the failure mechanisms and propagation pathways, facilitating the optimization of battery design and safety features. And help OEMs to evaluate battery performance for internal and external short circuit during crash events helps in optimal way and evaluate critical TR of the battery system.