Skip to main content

Advertisement

SpringerLink
Log in

Space mapping-assisted optimization of a thin-walled honeycomb structure for battery packaging

  • Industrial Application Paper
  • Published:
Structural and Multidisciplinary Optimization Aims and scope Submit manuscript

Abstract

A new thin-walled honeycomb structure for Li-ion battery packaging is designed and optimized in this study. Compared with other battery packaging structures, the designed honeycomb structure described here uses a grid to reinforce its strength. At the same time, the weight is reduced to improve the energy density of the entire package. Moreover, the new thin-walled structure can better protect the internal battery and improve the safety of an electric vehicle (EV). A space mapping (SM) algorithm is used to efficiently optimize the thin-walled honeycomb structure due to the expensive computational cost of each evaluation of a fine FE model. Compared with other SM algorithms, the coarse model of SM is based on a pseudo-plane-strain model. The result shows that the magnitude of stress and the distribution of stress are significantly improved compared with the initial structure. Moreover, the computational cost of optimization for the problem is also decreased significantly due to importing the coarse model.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14

Similar content being viewed by others

References

  • Ali MY, Lai WJ, Pan J (2013) Computational models for simulations of lithium-ion battery cells under constrained compression tests. J Power Sources 242(22):325–340

    Article  Google Scholar 

  • Ali MY, Lai WJ, Pan J (2015) Computational models for simulation of a lithium-ion battery module specimen under punch indentation. J Power Sources 273:448–459

    Article  Google Scholar 

  • Amiri S, Chen X, Manes A et al (2016) Investigation of the mechanical behaviour of lithium-ion batteries by an indentation technique. Int J Mech Sci 105(6):1–10

    Article  Google Scholar 

  • Bakr MH, Bandler JW, Biernacki RM et al (1998) A trust region aggressive space mapping algorithm for EM optimization. Microwave Theory & Techniques IEEE Transactions on 46(12):2412–2425

    Article  Google Scholar 

  • Bandler JW, Biernacki R, Chen SH et al (1994) Space mapping technique for electromagnetic optimization. IEEE Trans Microw Theory Techn 42(12):2536–2544

    Article  Google Scholar 

  • Baroutaji A, Sajjia M, Olabi AG (2017) On the crashworthiness performance of thin-walled energy absorbers: recent advances and future developments. Thin-Walled Struct 118:137–163

    Article  Google Scholar 

  • Chuang CH, Huang JS (2002) Effects of solid distribution on the elastic buckling of honeycombs. Int J Mech Sci 44(7):1429–1443

    Article  Google Scholar 

  • Dharmasena KP, Wadley HNG, Xue Z et al (2008) Mechanical response of metallic honeycomb sandwich panel structures to high-intensity dynamic loading. Int J Impact Eng 35(9):1063–1074

    Article  Google Scholar 

  • Fang J, Sun G, Qiu N et al (2017) On design optimization for structural crashworthiness and its state of the art. Struct Multidiscip Optim 55(3):1091–1119

    Article  MathSciNet  Google Scholar 

  • Florentie L, Blom DS, Scholcz TP et al (2016) Analysis of space mapping algorithms for application to partitioned fluid–structure interaction problems. Int J Numer Methods Eng 105(2):138–160

    Article  MathSciNet  Google Scholar 

  • Greve L, Fehrenbach C (2012) Mechanical testing and macro-mechanical finite element simulation of the deformation, fracture, and short circuit initiation of cylindrical lithium ion battery cells. J Power Sources 214(4):377–385

    Article  Google Scholar 

  • Ivañez I, Fernandez-Cañadas LM, Sanchez-Saez S (2017) Compressive deformation and energy-absorption capability of aluminium honeycomb core. Compos Struct 174:123–133

    Article  Google Scholar 

  • Koziel S, Bandler JW, Cheng QS (2010) Robust trust-region space-mapping algorithms for microwave design optimization. IEEE Trans Microw Theory Techniques 58(8):2166–2174

    Article  Google Scholar 

  • Leary SJ, Bhaskar A, Keane AJ (2001) A constraint mapping approach to the structural optimization of an expensive model using surrogates. Optim Eng 2(4):385–398

    Article  MathSciNet  Google Scholar 

  • Lee U, Kang N, Lee I (2019) Selection of optimal target reliability in RBDO through reliability-based design for market systems (RBDMS) and application to electric vehicle design. Struct Multidiscip Optim 60(3):949–963

    Article  Google Scholar 

  • Li G, Chakka VS (2010) Isogrid stiffened syntactic foam cored sandwich structure under low velocity impact. Compos Part A Appl Sci Manuf 41(1):177–184

    Article  Google Scholar 

  • Meier J D.2013 Material characterization of high-voltage lithium-ion battery models for crashworthiness analysis. Cambridge, Massachussetts, MIT,

  • Mendoza H, Roberts SA, Brunini VE et al (2016) Mechanical and electrochemical response of a LiCoO 2, cathode using reconstructed microstructures. Electrochim Acta 190:1–15

    Article  Google Scholar 

  • Mousanezhad D, Ghosh R, Ajdari A et al (2014) Impact resistance and energy absorption of regular and functionally graded hexagonal honeycombs with cell wall material strain hardening. Int J Mech Sci 89:413–422

    Article  Google Scholar 

  • Redhe M, Nilsson L.2002 Using space mapping and surrogate models to optimize vehicle crashworthiness design//9th AIAA/ISSMO Symposium on Multidisciplinary Analysis and Optimization. 5536

  • Sahraei E, Hill R, Wierzbicki T (2012a) Calibration and finite element simulation of pouch lithium-ion batteries for mechanical integrity. J Power Sources 201(3):307–321

    Article  Google Scholar 

  • Sahraei E, Campbell J, Wierzbicki T (2012b) Modeling and short circuit detection of 18650 Li-ion cells under mechanical abuse conditions. J Power Sources 220(4):360–372

    Article  Google Scholar 

  • Sahraei E, Meier J, Wierzbicki T (2014) Characterizing and modeling mechanical properties and onset of short circuit forthree types of lithium-ion pouch cells. J Power Sources 247(2):503–516

    Article  Google Scholar 

  • Sahraei E, Bosco E, Dixon B et al (2016) Microscale failure mechanisms leading to internal short circuit in Li-ion batteries under complex loading scenarios. J Power Sources 319:56–65

    Article  Google Scholar 

  • Shui L, Chen FY, Garg A, Peng XB, Bao NS, Zhang J (2018) Design optimization of battery pack enclosure for electric vehicle. Struct Multidiscip Optim 58(1):331–347

    Article  Google Scholar 

  • Sun Z, Shi S, Guo X et al (2016) On compressive properties of composite sandwich structures with grid reinforced honeycomb core. Compos Part B Eng 94:245–252

    Article  Google Scholar 

  • Tang L, Zhang J, Cheng P (2017) Homogenized modeling methodology for 18650 lithium-ion battery module under large deformation. PLoS One 12(7):e0181882

    Article  Google Scholar 

  • Wang L, Liu B, Xu J. 2016 A finite element model of 18650 lithium-ion battery for explosion caused by internal short circuit. ASME 2016, International Conference on Ocean, Offshore and Arctic Engineering. V009T12A012

  • Wang H, Fan T, Li G (2017) Reanalysis-based space mapping method, an alternative optimization way for expensive simulation-based problems. Struct Multidiscip Optim 55(6):2143–2157

    Article  Google Scholar 

  • Wierzbicki T, Sahraei E (2013) Homogenized mechanical properties for the jellyroll of cylindrical lithium-ion cells. J Power Sources 241(6):467–476

    Article  Google Scholar 

  • Xu J, Liu B, Wang X et al (2016) Computational model of 18650 lithium-ion battery with coupled strain rate and SOC dependencies. Appl Energy 172:180–189

    Article  Google Scholar 

  • Yaji K, Yamasaki S, Tsushima S, Suzuki T, Fujita K (2018) Topology optimization for the design of flow fields in a redox flow battery. Struct Multidiscip Optim 57(2):535–546

    Article  MathSciNet  Google Scholar 

  • Yamashita M, Gotoh M (2005) Impact behavior of honeycomb structures with various cell specifications—numerical simulation and experiment. Int J Impact Eng 32(1–4):618–630

    Article  Google Scholar 

  • Zhang C, Santhanagopalan S, Sprague MA et al (2015a) Coupled mechanical-electrical-thermal modeling for short-circuit prediction in a lithium-ion cell under mechanical abuse. J Power Sources 290:102–113

    Article  Google Scholar 

  • Zhang C, Santhanagopalan S, Sprague MA et al (2015b) A representative-sandwich model for simultaneously coupled mechanical-electrical-thermal simulation of a lithium-ion cell under quasi-static indentation tests. J Power Sources 298:309–321

    Article  Google Scholar 

  • Zhao R, Liu J, Gu J (2016) Simulation and experimental study on lithium ion battery short circuit. Appl Energy 173:29–39

    Article  Google Scholar 

  • Zhu J, Wierzbicki T, Li W (2018) A review of safety-focused mechanical modeling of commercial lithium-ion batteries. J Power Sources 378:153–168

    Article  Google Scholar 

Download references

Acknowledgments

This work has been supported by Project of the Program of National Natural Science Foundation of China under the Grant Nos. 11972155 and 51621004 and Key Projects of the Research Foundation of Education Bureau of Hunan Province (17A224).

Author information

Authors and Affiliations

  1. College of Mechanical & Electrical Engineering, Central South University of Forestry and Technology, Changsha, 41004, People’s Republic of China

    Wenquan Shuai & Enying Li

  2. State Key Laboratory of Advanced Design and Manufacturing for Vehicle Body, Hunan University, Changsha, 410082, People’s Republic of China

    Wenquan Shuai, Hu Wang & Yu Li

  3. Joint Center for Intelligent New Energy Vehicle, Shanghai, China

    Hu Wang

Authors
  1. Wenquan Shuai
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Enying Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Hu Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Yu Li
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Enying Li.

Ethics declarations

Conflict of interest

The authors declare that they have no conflict of interest to this work.

Replication of results

The data of the analysis and optimization, which can be repeatable, are provided as supplementary material. Due to the secrecy of project, the experimental data would not be provided in this work.

Additional information

Responsible Editor: Qing Li

Publisher’s Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Shuai, W., Li, E., Wang, H. et al. Space mapping-assisted optimization of a thin-walled honeycomb structure for battery packaging. Struct Multidisc Optim 62, 937–955 (2020). https://doi.org/10.1007/s00158-020-02509-3

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00158-020-02509-3

Keywords

Search

Navigation