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LS-DYNA Electric Vehicle Battery Pack Crash Protection

30 Chapters
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01
Course overview
scope, concepts, and technical context.
technical
02
Technical foundations
relevant concepts, terminology, and applications.
Technicalfoundations
03
Battery pack architecture and crash protection requirements
cell, module, pack, enclosure, and vehicle integration.
architectureprotection
04
Crash load cases and regulatory landscape
frontal, side, rear, bottom impact, and GB 38031 / FMVSS 305 / UN R100.
regulatorylandscape
05
LS-DYNA solver fundamentals for battery pack crash simulation
explicit dynamics, time step control, and mass scaling.
LS-DYNAsimulation
06
Material modeling for battery pack components
steel, aluminum, composites, plastics, and foams.
Materialmodeling
07
Battery cell and module modeling strategies
homogenized, detailed, and hybrid approaches.
modelingstrategies
08
Contact definitions and interface modeling for battery pack assemblies
tied, sliding, eroding, and single surface.
definitionsinterface
09
Meshing strategies for battery pack crash models
shell, solid, and SPH elements.
strategiesSPH
10
Boundary conditions and loading application for battery pack crash scenarios.
Boundary conditions and loading application for battery pack crash scenarios.
Boundaryconditions
11
Intrusion and deformation criteria for battery pack enclosure and modules.
Intrusion and deformation criteria for battery pack enclosure and modules.
Intrusiondeformation
12
Electrical short circuit and thermal runaway risk assessment in crash simulation.
Electrical short circuit and thermal runaway risk assessment in crash simulation.
Electricalassessment
13
Modeling of busbars, connectors, and high-voltage cables under crash loading.
Modeling of busbars, connectors, and high-voltage cables under crash loading.
Modelingconnectors
14
Cooling system and coolant line crash integrity simulation.
Cooling system and coolant line crash integrity simulation.
integritysimulation
15
Enclosure design for crash protection
material selection, thickness, and structural optimization.
Enclosureprotection
16
Module mounting and fixation strategies
bolts, adhesives, and welding under impact.
mountingfixation
17
Cell-level mechanical abuse simulation
indentation, penetration, and compression.
Cell-levelmechanical
18
Side pole impact simulation for battery pack protection.
Side pole impact simulation for battery pack protection.
simulationprotection
19
Frontal crash simulation for battery pack protection.
Frontal crash simulation for battery pack protection.
simulationprotection
20
Rear and bottom impact simulation for battery pack protection.
Rear and bottom impact simulation for battery pack protection.
simulationprotection
21
Ground clearance and underbody protection simulation.
Ground clearance and underbody protection simulation.
clearanceunderbody
22
Drop and vibration test simulation for battery pack durability.
Drop and vibration test simulation for battery pack durability.
vibrationsimulation
23
Thermal runaway propagation simulation coupled with crash-induced damage.
Thermal runaway propagation simulation coupled with crash-induced damage.
propagationsimulation
24
Multi-physics coupling
structural, thermal, and electrical interactions in LS-DYNA.
Multi-physicscoupling
25
Optimization techniques for battery pack crashworthiness
DOE, topology, and shape optimization.
Optimizationtechniques
26
Validation and verification of battery pack crash models
material tests, component tests, and full-scale tests.
Validationverification
27
Correlation and model updating using experimental data.
Correlation and model updating using experimental data.
Correlationupdating
28
Case study
side impact battery pack protection design and simulation.
protectionsimulation
29
Case study
frontal crash battery pack protection design and simulation.
protectionsimulation
30
Future trends and advanced topics
solid-state batteries, lightweight materials, and AI-driven simulation.
advancedsolid-state