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PAM-CRASH EV Battery Impact and Safety Simulation

30 Chapters
View Course Samples Online
01
EV battery safety simulation with PAM-CRASH
course scope, regulatory drivers, and simulation workflow overview.
simulationPAM-CRASH
02
PAM-CRASH explicit solver fundamentals
time integration, contact algorithms, and hourglass control for crashworthiness analysis.
PAM-CRASHexplicit
03
Battery pack CAD preparation and meshing in PAM-CRASH
geometry cleanup, shell and solid element selection, and mesh quality criteria.
CADpreparation
04
Material modeling for battery enclosure structures
elastic-plastic metals, strain-rate dependence, and failure criteria calibration.
Materialmodeling
05
Lithium-ion cell representation in PAM-CRASH
homogenized jellyroll models, equivalent mechanical properties, and validation against cell-level tests.
Lithium-ionrepresentation
06
Battery module and pack assembly modeling
joints, fasteners, adhesives, and contact definitions for impact simulation.
assemblymodeling
07
Boundary conditions and loading scenarios for EV battery impact
drop, crush, penetration, and vibration input definitions.
Boundaryconditions
08
Side pole impact simulation of a full EV battery pack
setup, boundary conditions, and deformation energy analysis.
simulationboundary
09
Frontal crash simulation of battery pack integration
sled test correlation and structural integrity assessment.
simulationintegration
10
Bottom impact and ground strike simulation
road debris and curb strike scenarios using PAM-CRASH.
simulationscenarios
11
Thermal runaway initiation under mechanical abuse
coupling PAM-CRASH structural results with thermal propagation models.
initiationmechanical
12
Short circuit prediction from deformation
mapping crush-induced displacement to electrode contact and electrical fault modeling.
predictiondeformation
13
Battery pack intrusion analysis
displacement contours, strain localization, and critical clearance evaluation.
intrusionanalysis
14
Contact interface modeling for cell-to-cell and cell-to-enclosure interactions
friction, separation, and self-contact.
interfacemodeling
15
Spot weld and bolted joint failure simulation in battery enclosures
rupture criteria and post-failure behavior.
simulationenclosures
16
Adhesive bonding and structural foam modeling for battery pack crash energy absorption.
Adhesive bonding and structural foam modeling for battery pack crash energy absorption.
Adhesivestructural
17
High-voltage connector and busbar behavior under impact
deformation, disconnection, and arcing risk assessment.
High-voltageconnector
18
Cooling system integration in crash simulation
pipe rupture, coolant leakage, and fluid-structure interaction basics.
integrationsimulation
19
Design of experiments for battery pack crashworthiness
parameter screening using PAM-CRASH batch runs.
experimentscrashworthiness
20
Optimization of battery enclosure thickness and topology for impact safety using PAM-CRASH and CAE tools.
Optimization of battery enclosure thickness and topology for impact safety using PAM-CRASH and CAE tools.
Optimizationenclosure
21
Model validation and correlation with physical tests
drop tower, sled, and full-scale crash data.
validationcorrelation
22
Mesh convergence and solution accuracy in battery impact simulation
time step, element size, and energy balance checks.
convergencesolution
23
Post-processing in PAM-CRASH
injury criteria, intrusion metrics, and battery-specific safety indicators.
Post-processingPAM-CRASH
24
Regulatory and standards compliance simulation
GB 38031, UN R100, and FMVSS 305 scenarios.
Regulatorystandards
25
Battery pack vibration and shock simulation
random vibration, mechanical shock, and fatigue life estimation.
vibrationsimulation
26
Multi-physics coupling in PAM-CRASH
structural-thermal-electrical co-simulation for abuse scenarios.
Multi-physicscoupling
27
Lightweight battery enclosure design
aluminum, composite, and hybrid material impact performance simulation.
Lightweightenclosure
28
Case study
side impact of a production EV battery pack — model setup, simulation, and design improvement.
productionsimulation
29
Case study
bottom impact and thermal runaway propagation — integrated PAM-CRASH workflow and mitigation strategies.
propagationintegrated
30
Future trends in EV battery safety simulation
AI-assisted model calibration, real-time simulation, and digital twin integration.
simulationAI-assisted