End Plate Stiffness Testing via 1D Model Simulation
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Solution Overview
Problem
The existing end plates in battery modules face challenges in maintaining suitable stiffness to support the battery stack effectively, leading to potential deformation and explosion risks due to swelling of battery cells, and there is a need for a method to test the stiffness without manufacturing the module.
Innovation Solution
A testing apparatus that calculates and simulates the force-distance curves for end plates using a one-dimensional model, determining the equivalent spring constant and deformation amounts to assess if the end plate meets design standards, allowing for the identification of necessary adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the stiffness of the end plate is increased to support the battery stack, then the end plate can better withstand deformation forces, but the battery cell swelling is excessively restricted which may cause explosion
Solution Approach 1:
The patent applies preliminary action by calculating and determining the appropriate stiffness of the end plate before the battery module is manufactured. The stiffness calculation considers the number of battery cells, individual cell spring constants, and expected swelling forces, allowing the end plate design to be optimized in advance to prevent both excessive deformation and explosion risks.
Solution Approach 2:
The patent employs parameter changes by dynamically adjusting the end plate stiffness parameters based on the specific configuration of battery cells. The stiffness is calculated using the spring constant of battery cells and the number of cells in the stack, allowing the end plate properties to be tailored to match the actual swelling characteristics of the battery pack.
2Object-affected harmful factors
If the stiffness of the end plate is decreased to allow battery cell swelling, then the battery cell can expand without explosion risk, but the end plate may be easily damaged by deformation of the battery stack
Solution Approach 1:
The patent applies preliminary action by calculating and determining the appropriate stiffness of the end plate before the battery module is manufactured. The stiffness calculation considers the number of battery cells, individual cell spring constants, and expected swelling forces, allowing the end plate design to be optimized in advance to prevent both excessive deformation and explosion risks.
Solution Approach 2:
The patent employs parameter changes by dynamically adjusting the end plate stiffness parameters based on the specific configuration of battery cells. The stiffness is calculated using the spring constant of battery cells and the number of cells in the stack, allowing the end plate properties to be tailored to match the actual swelling characteristics of the battery pack.
3Measurement precision
If a physical battery module is manufactured to test end plate stiffness, then accurate stiffness measurement can be obtained, but manufacturing time and cost are significantly increased
Solution Approach 1:
The patent applies copying by creating a virtual model that replicates the mechanical behavior of the battery module. Instead of manufacturing physical prototypes for testing, the system uses a computational model that copies the essential characteristics of battery cell swelling and end plate deformation, allowing stiffness evaluation without physical assembly.
Solution Approach 2:
The patent replaces the mechanical testing system with a computational calculation system. The physical act of manufacturing and testing end plate stiffness is substituted with mathematical calculations that use spring constants and force-distance relationships to determine stiffness, eliminating the need for physical prototypes while maintaining measurement accuracy.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the determination of end plate stiffness to withstand battery cell swelling loads and deformation without manufacturing the module, ensuring compliance with design standards and preventing potential explosions.
Implementation Method 1
a second parameter representing a spring constant of a battery cell of the battery cells included in the battery module and a third parameter representing a spring constant of the end plate
Implementation Method 2
the one-dimensional model is to simulate a structure in which a front surface and a rear surface of a battery stack are supported by the end plate
Data Source
AI summary
An apparatus and method for testing the strength of an end plate mounted in a battery module. The apparatus includes a memory unit configured to store a first parameter representing a number of battery cells included in the battery module, a second parameter representing a spring constant of a battery cell and a third parameter representing a spring constant of the end plate, and a control unit configured to generate a one-dimensional model associated with the battery module based on the first parameter, calculate a first F-D curve based on the second and third parameters and the one-dimensional model, and store first reference data representing the first F-D curve in the memory unit. The first F-D curve corresponds to a relationship between a deformation amount and a load of the end plate according to the number of battery cells represented by the first parameter.