Battery Durability & Safety: Simulation for Excellence
Batteries are not only the source of power of the vehicle, but they are also the most expensive component. Furthermore, regulations around the globe require car manufacturers to protect the batteries with warranties that can go up to 10 years. These factors set battery durability under huge pressure as recall campaigns can be extremely expensive and may lead to loss of trust from potential customers for the entire vehicle range of the OEM, not only for the involved models. It is then of paramount importance to early discover potential design flaws by extensive use of simulations techniques. These techniques allow, well in advance of the availability of any real prototype, to expose batteries to the most severe vibrations and temperature levels; hotspots and weak connections can be immediately identified, and countermeasures taken before any real issue arises.
Early design explorations also allow guaranteeing safety of this critical component both in terms of mechanical abuse, e.g., impact from underneath, and thermal, e.g., optimizing the number and locations of the venting caps.