Impact simulation of passenger electric vehicle’s battery pack protective structure for speed bump crossing event

In the automotive industry, the electric vehicle is the new era, and companies are committed to reducing carbon emissions by electrification of their vehicles. In the development of electric vehicles, the battery is the central power source for all the parts of the vehicle. Usually, it is placed under the body because of its size and mass. So, it is important to protect battery cells from leakage and damage from obstacles. For on-road electric vehicles, speed bumps are one of the crucial obstacles. This paper investigates and analyses the protection of battery pack systems in electric vehicles while encountering speed bump profiles at different speeds. During the physical test on a speed bump, there is a possibility of bump hit on the battery pack system and it is necessary to ensure the structural safety of the battery pack systems. In this study, CAE method has been developed to validate the battery pack system in the event of a speed bump crossing. Virtual simulation analysis was performed in the full vehicle FE model and measured the impact energy at various locations and acceleration on the battery pack. Virtual results are well correlated with test measurements at various locations on the battery pack system. Based on the correlation results, CAE provides design suggestions and verified in physical test.