Ensuring battery pack reliability requires validation under real-world vibration and operating conditions. Our approach integrates advanced simulation with physical test correlation to accurately predict structural performance and fatigue life. By leveraging hybrid modeling and efficient analysis methods, we achieve high-fidelity results with significantly reduced computation time.

Key Highlights:

• Validation-Driven Approach: Battery packs evaluated under real-world vibration environments using accelerometer data to support simulation inputs and shaker table testing.
• Hybrid Modeling Strategy: Combined detailed finite element models with super-element techniques to reduce model size, simulation time, and storage requirements.
• Efficient Dynamic Analysis: Applied modal transient analysis with superposition to capture dynamic behavior while minimizing computational cost.
• Super-Element Implementation: Modeled a single battery module in detail while representing others as super-elements, enabling rapid fatigue evaluation and faster design iterations.
• Correlation & Accuracy: Simulation results correlated closely with physical test data, ensuring confidence in fatigue life predictions and overall structural performance.