Designed and validated advanced battery packs with under-frame cradle, steel enclosure, aluminum under-floor, and steel/SMC cover architectures. Development addressed crashworthiness, durability, and thermal performance, ensuring safe EV integration.

Key Highlights:

• Aluminum structure and side sill/cross member design for energy absorption
• Energy- and crush-based targets for simultaneous BIW and battery enclosure engineering
• Multiple impact locations analyzed for robustness and electrocution safety
• Casting design, riveted/bonded connections, and failure analysis of extrusions and castings
• Boundary conditions simulating body attachments; early module representation via nodal mass
• Structural strength under vertical, lateral, fore-aft ‘g’ loads; modal/resonance analysis
• Durability: multi-directional ‘g’ loads, shaker table PSD and sine sweep fatigue
• Dynamic 50g shock loading; crash validation (rear suspension impact, curb hit)
• Leak-proof and pressure release valve testing; altitude testing
• Thermal evaluation: aluminum design with chill plates, hand calcs + CFD for flow optimization, cell temperature variation tracking, thermal paste effects, module-to-pack thermal performance