Determining the structural life of an electric vehicle battery from road loads

H. Zınar Düzgün; Polat Şendur

doi:10.1515/mt-2022-0023

Article

Determining the structural life of an electric vehicle battery from road loads

H. Zınar Düzgün
H. Zınar Düzgün received the BSc degree in automotive engineering from Hacettepe University in 2016. After graduation, he worked for different companies including S-T Engineering, Ford Motor Company and TOGG. His research interest is related to durability road load data engineering. He has experience on simulation software such as Virtual Proving Ground Analysis and Time Waveform Replication Analysis for heavy commercial vehicles and passenger cars. In addition, he worked on various customer correlation projects for vehicle level durability tests. He is currently pursuing M.Sc. degree in mechanical engineering in Ozyegin University and working for TOGG.
and Polat Şendur
Polat Şendur received the BSc degree in mechanical engineering from Middle East Technical University, Turkey, in 1996, and the MSc and PhD degrees from The University of Michigan, USA, in 1998 and 2002, respectively. He was a Simulation Expert with Tec-Masters, Inc., USA, from 2002 to 2004. From 2004 to 2006, he worked with Robert Bosch Corporation, USA. From 2006 to 2016, he worked as Team Leader with Vehicle Dynamics and NVH, Ford Otosan, Turkey. Since 2016, he has been an Assistant Professor with the Mechanical Engineering Department, Ozyegin University, Istanbul, Turkey. His research interests include vibrations, acoustics, and system dynamics and modeling. Dr. Sendur has been awarded with a two-year Marie Curie International Re-Integration Grant for his project “Multi-Disciplinary Design Optimization of Adaptive Vehicle Safety Systems for Whiplash Associated Disorders (WAD)” in 2007.

Published/Copyright: July 7, 2022

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From the journal Materials Testing Volume 64 Issue 7

Abstract

Although the electrical system is important in the development of electric vehicles, the durability of the battery system against mechanical loads and the performance of the battery against shock reactions are just as important. The objective of this study is to develop a methodology to determine the structural life of the battery of the C-platform sports utility vehicle (SUV). For this purpose, a power spectral density (PSD) durability test profile is generated and compared to battery test standards such as ISO 6469:2019, AK-LH 5.21 and SAE J2380. Analytical Virtual Proving Ground (VPG), a multibody dynamics simulation model, is also developed and correlated to test data. The results show that FDS values for AK-LH is higher than the fatigue damage of the collected vehicle data, while the FDS results for ISO standard are lower compared to the vehicle data. The results also indicate that the loads in the longitudinal (x-direction) and lateral (y-direction) directions are different. Therefore, loads of different amplitudes should be used for these directions, contrary to SAE J2380 and USABC standards. Finally, it is concluded that the VPG model can be used for determining the fatigue life when there is no test data, thanks to its high accuracy.

Keywords: battery; durability testing; electric vehicle; fatigue testing; vibrations

Corresponding author: Polat Şendur, Ozyegin University, Cekmekoy 34794, Istanbul, E-mail: polat.sendur@ozyegin.edu.tr

About the authors

H. Zınar Düzgün

H. Zınar Düzgün received the BSc degree in automotive engineering from Hacettepe University in 2016. After graduation, he worked for different companies including S-T Engineering, Ford Motor Company and TOGG. His research interest is related to durability road load data engineering. He has experience on simulation software such as Virtual Proving Ground Analysis and Time Waveform Replication Analysis for heavy commercial vehicles and passenger cars. In addition, he worked on various customer correlation projects for vehicle level durability tests. He is currently pursuing M.Sc. degree in mechanical engineering in Ozyegin University and working for TOGG.

Polat Şendur

Polat Şendur received the BSc degree in mechanical engineering from Middle East Technical University, Turkey, in 1996, and the MSc and PhD degrees from The University of Michigan, USA, in 1998 and 2002, respectively. He was a Simulation Expert with Tec-Masters, Inc., USA, from 2002 to 2004. From 2004 to 2006, he worked with Robert Bosch Corporation, USA. From 2006 to 2016, he worked as Team Leader with Vehicle Dynamics and NVH, Ford Otosan, Turkey. Since 2016, he has been an Assistant Professor with the Mechanical Engineering Department, Ozyegin University, Istanbul, Turkey. His research interests include vibrations, acoustics, and system dynamics and modeling. Dr. Sendur has been awarded with a two-year Marie Curie International Re-Integration Grant for his project “Multi-Disciplinary Design Optimization of Adaptive Vehicle Safety Systems for Whiplash Associated Disorders (WAD)” in 2007.

Author contributions: All the authors have accepted responsibility for the entire content of this submitted manuscript and approved submission.
Research funding: None declared.
Conflict of interest statement: The authors declare no conflicts of interest regarding this article.

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Published Online: 2022-07-07

Published in Print: 2022-07-26

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Articles in the same Issue

https://doi.org/10.1515/mt-2022-0023

Keywords for this article

battery; durability testing; electric vehicle; fatigue testing; vibrations