Modeling and Analysis of the Battery Packs and Modules in A123 Systems

Binshan Ye & Shawn Zhang

A123 Systems, Inc.

Outline

Overview of CAE capacity in A123 CAE Modeling and Analysis Examples

Random vibration fatigue analysis with HWPA program (DesignLife) Cell material properties characterizing with HyperStudy

Concluding Remarks

A123 Engineering Simulation Capability

A123 Systems Engineering Simulation

CFD and Thermal Management

Battery Life Analysis

Finite Element Analysis

Cooling Concept Development and Validation Module and Pack Level Thermal and Flow Analysis

Battery Life Estimation Software Development

Linear Statics and Modal Frequency Random Vibration and Fatigue

Battery Life Analysis

Thermal/Electrical Coupling (Joule Heating)

Battery Electrical Performance Simulation

Mechanical Shock and Drop Analysis

Thermal Analysis for Electronics Cell R&D and External Supplier

Nonlinear Statics

Pack and Module Level FEA Analysis

Linear Statics and modal frequency analysis

Modal frequency analysis Foot/knee load, handle load, and lifting assistance analysis Topology/topography/shape/gauge optimization

Random vibration stress and fatigue analysis

RMS stress calculation Fatigue life calculation for metal parts

Mechanical shock, pothole, and drop analysis Nonlinear and contact analysis
Snap-in/pull-out force estimation Jack loading analysis Bolt assembly, module pressure plate, etc.

FEA Tools Used in A123 Systems

Altair HyperWorks Suite

Radioss/Bulk Radioss/Block OptiStruct HyperStudy

LS-DYNA3D ABAQUS (Implicit/Explicit) Access to other software through HyperWorks Partner Alliance License
nCode DesignLife Key to Metals Others

Altair PBS Pro

Random Vibration Analysis on Battery Pack

Battery Pack Vibration Analysis

A123 conducts random vibration stress and fatigue analysis according to customer specifications or industrial standards Approach
Use Radioss/Bulk to calculate RMS stresses from the PSD profiles Estimate fatigue life using nCode DesignLife if necessary

SAE J2380 PSD Profiles

Example Random Vibration Analysis

A prototype battery pack had a test failure on mounting brackets during random vibration test The analysis team was involved to identify the root causes of the failures and find the solution in a limited time frame

Challenges

A few locations on mounting brackets showed fatigue cracks Initial random vibration stress analysis showed the failure locations have high RMS stress during vibration events, but it cannot accurately quantify the fatigue life The fatigue properties for the metal components were unknown Project timing and budget wont allow performing material test to obtain the fatigue properties

Correlating the Fatigue Properties

nCode DesignLife was used to evaluate the fatigue life of metal components:
The stress-life properties were estimated in DesignLife based on material specs Random vibration fatigue engine was used to estimate the fatigue life of the metal components The fatigue properties and analysis parameters were then adjusted to correlate the analysis results with test results

Material Stress Life Curve Vibration Fatigue Analysis Engine

Result Comparisons
With correlated fatigue properties, the analysis identified all test failure locations:
The failure locations have relatively high RMS stresses comparing to material specs The fatigue lives in these locations are lower than the requirement

90% of required life

10% of required life

3 RMS stress : 55% of material uts Fatigue life: 90% of the required life

3 RMS stress: 72% of material uts Fatigue life: 10% of required life

Improve the Design Through Analysis

Based on the analysis results, new design concepts were proposed:
Change the shape of the components Add reinforcement brackets Change welding patterns

New pack design passed the random vibration fatigue analysis These design changes were implemented and the new pack went through random vibration test without fatigue issue

Infinite

65 li es

Prismatic !ell material Pro"erty !#aracteri$ation

Challenges for Battery Module Modeling

Modal frequency is critical for battery pack design, and battery modules play a significant role Cell property largely unknown Ideally, we would like to use a simple homogenized model to represent the complex structure of the module (cells, heat sinks, and bands) The first few modal frequencies of the module model should meet the test results

Two Module Modeling Approaches

Homogenized model
Cell, heat sink, compliance pad are homogenized into blocks End plate is modeled with shell elements as one plane sheet Module bolt is modeled with beam elements All materials are isotropic

Detailed model
Each component is modeled in detail with corresponding material properties End plate is modeled in detail with shell elements Module bolt is modeled with beam elements

Pro and Cons:

Can better predict module dynamic behavior Long modeling time due to complexity of the module High CPU and memory costs

Pros and Cons:

Can be quick modeled and use very little CPU time Accuracy is compromised due to simplification

Hybrid Module Modeling Approach

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Endplate modeled in detail by shell element Bolt was modeled by beam element with rod section Cell, heat sink, cell compliance pad, band were homogenized into a 3-d orthotropic material Local coordinate system was used for the orthotropic material modeling

Characterizing the Material

Three modules were tested with free-free and fixed BC

Large size module, medium size module, and small size module

For free-free boundary condition, the first 3 modes from test were used for FEA model correlation For fixed boundary condition, the first 5 modes from test were used in FEA model correlation Homogenized orthotropic material was formulated using the following engineering constants

Characterizing the Material

Goal was to adjust E1, E2, E3, G12, G13, G23 to correlate both the mode shapes and frequencies with test results. Observations during initial evaluation:
Some Eii, Gij, and vij have strong influence to long and medium size modules modal frequencies; Other Eii, Gij, and vij have significant effect to small module modal frequencies The remaining Eii, Gij, and vij have little effect to the first 3 modal frequencies at all. In that case, they are assigned to zero, leading to a simple material matrix

Material parameters were first manually adjusted to match modal shapes in order. Then HyperStudy was used to match first 3 frequencies more closely

Modal Correlation

HyperStudy

Modal Correlation

HyperStudy

Modal Correlation

HyperStudy

Results Correlations

Table-1: Relative Deviations of Estimated Modal Frequencies from Test Results under free-free condition

Free-free BC Large module Medium module Small module

1st Mode 0.6% 3.3% .27%

2nd Mode .48% 2.7% 5.9%

3rd Mode 0.% 1.5% 2.8%

Table-2: Relative Deviations of Estimated Modal Frequencies from Test Results under fixed condition

Fixed BC Large module Medium module Small module

1st Mode 4.5% 1.5% 0.1%

2nd Mode 10.7% 9.5% 7%

3rd Mode 1.6% 8.1% 8.1%

4th Mode 2.1% 17.5% --

5th Mode 0.3 % 24.2% --

Illustration of Typical Module Mode

Summary of Hybrid Module Model

This hybrid module model was a compromise among all 3 size modules, with deviation within 5% in free-free boundary condition The hybrid module model was more skewed to large size modules because for small size modules, the first frequency is very high already, making them less sensitive to external vibration. By using such approach, a battery module for pack analysis can be quickly modeled and still achieve good analytical results

Concluding Remarks

A123 has a broad range of engineering simulation capabilities to support battery pack/module development activities Altairs HyperWorks Suite and HWPA are the best cost-effective tools to match A123s FEA simulation requirements