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<p>The design and analysis of the Electric Bus Battery Pack (EBBP) poses significant challenges due to the need for performance optimization, safety enhancement, and extended battery pack life under varying environmental conditions. In this paper, a numerical fatigue life analysis of an EBBP has been investigated subjected to random vibration, based on the ISO 6469-1 standard. 21,700 cylindrical cells are used to design the EBBP model in SolidWorks. Finite Element Analysis (FEA) has been conducted using Abaqus software to perform natural frequency analysis and steady-state dynamics simulations. The results were then used in FE-Safe software to calculate the fatigue life. The response of the EBBP to random vibrations in X, Y, and Z directions using the ISO 6469-1 Power Spectral Density (PSD) profiles was determined. The Frequency Response Functions (FRF) for a unit acceleration based on EBBP for its resonance characteristics have been evaluated. The predicted fatigue life, which is calculated using the Dirlik method, indicates that the structure of the battery pack is robust, with fatigue life exceeding the ISO standards. Results of this paper provide insights for future optimization of the design and material selection of the EBBP, ensuring enhanced performance and durability in real-world operational conditions.</p>

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Numerical Fatigue Life Analysis for Battery Pack of Electric Bus Under Random Vibration

  • 期刊论文

  • 发表日期：

    2025年10月31日

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  • E. Abbasi Shahisaraei,
  • M. Esfahanian,
  • S. Ziaei-Rad

摘要

The design and analysis of the Electric Bus Battery Pack (EBBP) poses significant challenges due to the need for performance optimization, safety enhancement, and extended battery pack life under varying environmental conditions. In this paper, a numerical fatigue life analysis of an EBBP has been investigated subjected to random vibration, based on the ISO 6469-1 standard. 21,700 cylindrical cells are used to design the EBBP model in SolidWorks. Finite Element Analysis (FEA) has been conducted using Abaqus software to perform natural frequency analysis and steady-state dynamics simulations. The results were then used in FE-Safe software to calculate the fatigue life. The response of the EBBP to random vibrations in X, Y, and Z directions using the ISO 6469-1 Power Spectral Density (PSD) profiles was determined. The Frequency Response Functions (FRF) for a unit acceleration based on EBBP for its resonance characteristics have been evaluated. The predicted fatigue life, which is calculated using the Dirlik method, indicates that the structure of the battery pack is robust, with fatigue life exceeding the ISO standards. Results of this paper provide insights for future optimization of the design and material selection of the EBBP, ensuring enhanced performance and durability in real-world operational conditions.