Structural assessment of electric two-wheeler battery enclosure: thermal and structural study

Abstract

AbstractIn recent times, electric two-wheelers (ETWs) are changing the face of the global automotive market. This study focused on selecting the proper material and mechanical isolation gap to design a protective enclosure for the battery pack of ETW. The integration of the failure, modes, mechanism and effect analysis (FMMEA) method is utilized to develop the interface matrix and the severity index of different components of the enclosure. By analysing different forces from the road conditions, dynamics during turn, acceleration and deceleration with the enclosure, it becomes a crucial load-bearing element. Employing finite element modelling (FEM), structural strength using materials like AL6061, Q235, C22000, DC01 and Teflon is assessed under varying static, dynamic and thermal conditions. Modal analysis is conducted to observe the excitation frequencies where the maximum deformation for the metal enclosure is observed beyond 500 Hz. AL6061 material that can withstand the stresses and deformations that are under allowable stress limits with negligible deformation is the most preferable material based on the results. A minimum of 2.5-mm gap is to be provided in case of metal enclosure and 10 mm in case of Teflon is proven.