Compared to an internal combustion engine, an EV must absorb more energy through the car’s sill. So it becomes pertinent to protect the battery pack from impacts.
Fremont, CA: The battery packs for battery electric vehicles (BEVs) are getting bigger for longer ranges. As a result, engineers face the challenge of protecting the battery cells during the crash. Even in a very demanding side pole impact test, the battery cells cannot be impacted. The EV concept is a virtual platform that encompasses innovative ideas and basic research on AHSS solutions for BEVs. With the help of Docol 1700 Martensitic that is 3D roll-formed into beams and welded into a mesh pattern, manufacturers have designed prototypes for a unique AHSS battery enclosure with a bottom structure. The rollers can move in all directions in a 3D roll-forming machine while forming the steel.
Manufacturers have used 3D roll-forming to create one part fixed and one part flexible beam. Further, placing beams perpendicular to one another in an upside-down position without doubling its height in the Z-direction. If battery enclosures are tall, that either creates a taller, less streamlined vehicle or reduces space in the passenger compartment.
Ensuring safety from impacts from below the car, the mesh 3D beams maintain a specified distance between the enclosure’s bottom plate and its battery ray. The load paths in X and Y directions are unbroken and robust as the grooves run along the length of each beam. To provide impact protection and a stabilized structure, a frame made from 1700M runs around the battery tray. To optimize the space for the battery pack, the enclosure tray is made from steel and drawn to form completely vertical or 90-degree sidewalls. In the events of a crash, the tray prevents the battery cells from leaking into the environment.
As compared to an internal combustion engine, an EV must absorb more energy through the car’s sill. Extruded aluminum is an efficient way of absorbing higher energy levels, but at a steep price as compared to AHSS.Manufacturers have tried to match the performance of extruded aluminum sill beams made from EN AW-6082 T6 with a thickness of 4.5mm for the outer walls and 3mm for its ribs. Using innovative 3D roll-forming AHSS to fabricate cross meshes will open up the way designers think about achieving maximized axial load performance.