The crush and vibration simulations are performed, and the FE analysis data are obtained. First, a nonlinear finite element (FE) model of a BPS is developed and experimentally verified. This method can obtain better combinations of the thicknesses of the BPS components, which helps engineers achieve robust and efficient designs. In this study, a dual-objective optimization method based on non-dominated sorting genetic algorithm II (NSGA-II) is proposed to evaluate the crushing stress of BPS modules and the vibration fatigue life of the BPS. Most studies evaluate the mechanical properties of BPSs under a single operating condition. The mechanical failure of battery-pack systems (BPSs) under crush and vibration conditions is a crucial research topic in automotive engineering. The development of additive manufacturing technology has provided opportunities for researchers to produce an optimal cellular structure commercially soon. Limited manufacturing capabilities encourage researchers to design an optimal cellular structure to be applied to a particular function but have high manufacturability. In this paper, the authors examine the state-of-the-art technology in geometry, applications, and manufacturing of various cellular structures carried out by researchers to obtain an overview of the current conditions for further development of these cellular structures. The challenges that limit the application of cellular structures today include systematically designing pseudo-random cellular structures, assessing which cellular patterns are most suitable for a particular application, and mastery of manufacturing technology for efficient mass production of cellular structures. In the automotive sector, cellular structures have been used for structural applications and impact- absorbing modules, for example, for protecting the electric vehicle battery pack against impact loading. Various applications of cellular structures can be found in aviation, bioengineering, automotive, and other fields. Each type of structure has its characteristics. Conclusions are made and research recommendations are proposed for the future work.Ĭellular structures can be classified into foams, honeycombs, and lattice structures. In the fourth phase, the optimum combination of inputs obtained by using NSGA II is used for the manufacturing of battery pack enclosure. In the third phase, the models based on CCD and ANN for the maximum deformation, minimum natural frequency and mass are further optimized by using non-dominated sorted genetic algorithm (NSGA II). In the second phase, the best combination of methodology (CCD and ANN) is then selected for experimental design and the empirical models are formulated for three features of mechanical design. central composite design (CCD) and response surface methodology (RSM), CCD and artificial neural network (ANN), Latin hypercube sampling (LHS) and RSM, LHS and ANN). In the first phase, finite element models for maximum deformation (based on static analysis), minimum natural frequency (based on modal analysis) and the mass are developed by using the combination of four methods (i.e. The proposed methodology is comprised of four phases. minimization of mass, maximization of minimum natural frequency and minimization of maximum deformation) of the battery pack enclosure. In this study, a design optimization methodology is proposed to optimize the features of mechanical design (e.g. In addition, lighter weight vehicle is preferred because it can increase the range of vehicle and the life cycle of a battery pack. The vehicle safety heavily depends on on the safety of battery pack which in turn is dependent on its mechanical features, such as the ability to resist deformation and vibration shocks. This will result in stresses and deformations of different degrees. During the actual operation of electric vehicle, the battery packs and its enclosure is subjected to harsh environmental conditions such as the external vibrations and shocks due to varying road slopes. Lithium-ion Battery pack which is comprised of assembly of battery modules is the main source of power transmission for electric vehicles.
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