Q/SZJ191001-2017電池包振動疲勞分析規(guī)范SpecificationofVibrationFatigueAnalysisforBatteryPack20XX20XX-XX-XX實施20XX-XX-XX發(fā)布XXXX汽車工程技術(shù)有限公司發(fā)布Q/SZXX-X-2017電池包振動疲勞分析規(guī)范范圍本標(biāo)準(zhǔn)規(guī)定了純電動車或混動車動力電池包振動疲勞分析的方法和要求。本標(biāo)準(zhǔn)適用于CAE部門電池包振動疲勞分析。規(guī)范性引用文件GB/T31467.3電動汽車用鋰離子動力蓄電池包和系統(tǒng)第3部分：安全性要求與測試方法術(shù)語和定義電池包通常包括電池組，電池組管理模塊（不包含BCU），電池箱體以及相應(yīng)附件，具有從外部獲得電能，并可對外輸出電能的單元。Aunitwhich,usuallyconsistingofbatterygroup,batterymanagementmodule(excl.BCU),batteryenclosureandcorrespondingaccessories,couldfetchelectricalenergyformoutsideandcouldexternallyoutputelectricenergy.3.2振動疲勞振動疲勞是結(jié)構(gòu)在振動載荷激勵下，產(chǎn)生的一種具有損傷累積性質(zhì)的振動強度破壞現(xiàn)象。它是結(jié)構(gòu)的疲勞破壞與結(jié)構(gòu)的振動響應(yīng)密切相關(guān)的失效現(xiàn)象。振動疲勞分為共振和非共振振動疲勞，低頻和高頻振動疲勞。摘要Abstract本規(guī)范根據(jù)GB/T31467.3-2015，規(guī)定了電池包振動疲勞分析的方法和流程，包括分析模型的建模要求，約束邊界條件，分析工況，載荷以及結(jié)果評價等。Thespecificationprovidesthevibrationfatigueanalysisflowandmethodforbatterypack,whichcontainsmodelingrequirements，boundarycondition,loading,resultevaluationandsoon.流程圖ProcessFlowDiagramYesYesNo電池包CAD模型BatteryPackCADModel電池包FEA模型BatteryPackFEAModel頻響分析/響應(yīng)應(yīng)力FRF/ResponseStress電池包振動疲勞模型VibrationFatigueModelofBatteryPack材料疲勞特性MaterialFatigueProperty結(jié)果是否滿足要求？TheresultisOK？結(jié)束End優(yōu)化Optimization功率譜密度PSD圖1流程圖Fig1ProcessFlowDiagram工具描述ToolDescription仿真分析過程中需要用到的如下軟件:Thefollowingsoftwarefacilitatestheanalyticalsimulationprocess:前處理(Preprocessors):Hypermesh求解器(AnalysisCode):Optistruct/nCode后處理(Postprocessors):HyperView建模和分析過程Modeling/AnalysisProcedure單位Units分析中所用單位制如下所示:Theunitsusedintheanalysisareasfollows:力(Force) 牛(N)質(zhì)量(Mass) 噸(Ton)長度(Length) 毫米(mm)時間(Time) 秒(Second)內(nèi)容Contents分析模型包括電池包上下殼體，內(nèi)部模組，內(nèi)部連接支架，試驗夾具等，模型如圖1所示Theanalysismodelcontentincludesthetopandbottomcovers,internalmodules,internalconnectionbrackets,testclamperandsoon.Themodelisshowninfigure1.圖2電池包有限元模型Fig2BatteryPackFEA坐標(biāo)系CoordinateSystems整車坐標(biāo)系Globalcoordinatesystem建模技巧ModelingTechniques網(wǎng)格質(zhì)量要求，平均單元尺寸3-8mm，翹曲小于12°，雅克比大于0.6，局部應(yīng)力區(qū)域沒有三角形單元，關(guān)鍵安裝點周圍沒有三角形單元，模型三角形單元數(shù)量小于10%，增加一圈washer在螺栓孔上。螺栓用Rbe2+Cbar單元模擬，焊縫用Penta焊縫類型模擬，簡化結(jié)構(gòu)用Rbe3+Mass模擬。Meshqualityrequirements,Averageelementsizeis3to8mm,Warpage<12,Jacobin>0.6,Notrianglesinlocalstressarea,notriangularelementsaroundkeyfixpoint,Triangleselement<10%,Addonewasherforboltholes.BoltusesRBE2+Cbarelementtosimulate.WeldusesPentatypetosimulate.SimplestructureusesRBE3+Masselementtosimulate.假設(shè)和限制Assumptions/Limitations假設(shè)Assumptions與物理試驗相比較，對于焊點焊縫失效和鈑金局部撕裂的地方，分析模型假設(shè)沒有焊點焊縫失效和鈑金撕裂。Incomparisonwiththephysicaltest,wherespotweldsmailfailandmaterialmaylocallytear,theanalyticalmodelassumesnoweldsfailureandnomaterialtear.限制Limitations材料非線性屬性被賦予電池包分析模型。NonlinearmaterialpropertiesareassignedtothebatterypackFEA.載荷和邊界條件Loads/BoundaryConditions約束Constrain約束夾具與試驗臺安裝螺栓孔1-6DOFAllboltswhichlinkbatterypacktotestplatformconstrain1-6DOF載荷Load在Nastran軟件中，對電池包與車身連接點進(jìn)行X/Y/Z三個方向的頻響分析，激勵頻率為0-200Hz，計算頻率響應(yīng)應(yīng)力，并提取激勵點X/Y/Z向的加速度。在nCode軟件中，輸入Nastran計算結(jié)果和功率譜密度（PSD），見表1，表2和表3，單通道循環(huán)次數(shù)設(shè)置為21H，存活率設(shè)置為90%，計算電池包損傷值。InNastransoftware,tothepointswherelinkbatterypacktocarbody,dothefrequencyresponseanalysisinX/Y/Zthreedirections.Excitationfrequencyis0to200Hz.TocalculatethefrequencyresponsestressandextracttheaccelerationofexcitationpointinX/Y/Zthreedirections.InnCodesoftware,calculatingthedamagevalueofthebatterypack.InputtheNastranresultandPSD(Table1,Table2,Table3)cycletimeissetas21heverychannel,survivalrateissetas90%.表1x軸PSD值Table1PSDvaluesofxaxis頻率FrequencyHz功率譜密度Powerspectraldensity(PSD)g2/Hz功率譜密度Powerspectraldensity(PSD)(m/s2)2/Hz50.01251.20100.032.89200.032.892000.000250.02RMS0.9.42m表2y軸PSD值Table2PSDvaluesofyaxis頻率FrequencyHz功率譜密度Powerspectraldensity(PSD)g2/Hz功率譜密度Powerspectraldensity(PSD)(m/s2)2/Hz50.010.96100.0151.44200.0151.44500.010.962000.00040.04RMS0.95g9.32m表3z軸PSD值Table3PSDvaluesofzaxis頻率FrequencyHz功率譜密度Powerspectraldensity(PSD)g2/Hz功率譜密度Powerspectraldensity(PSD)(m/s2)2/Hz50.054.81100.065.77200.065.772000.00080.08RMS1.14.13mnCode中計算流程圖如下所示Calculationflowchartasshowninthefollowingfigure3圖3nCode計算流程圖Fig3RunFlowDiagraminnCode結(jié)果Results輸出HyperMesh.hyp文件，輸出疲勞損傷值。OutputfatiguedamagevalueinHyperMesh.hypfile.性能要求PerformanceRequirements電池包及支架上的最大損傷值小于0.2。TheMaxdamagevalueofbatterypackandbracketless0.2.分析要求ANALYSISREQUIREMENTS無。參考文件DOCUMENTATIONGB/T31467.3-2015電動汽車用鋰離子動力蓄電池包和系統(tǒng)第3部分：安全性要求與測試方法GB32087-2015Lithium-iontractionbatterypackandsystemforelectricvehicles聯(lián)系人CONTACTS無。例子EXAMPLES$FREQUENCYRESPONSESOL111$DOMAINSOLVERACMS(PARTOPT=DOF,PRINT=YES)CENDSET1=80979242,80979243,80979244,80979245,80979246,80979247$HMSET12"SET"$HMSETTYPE1"regular"$ECHO=NONESPC=1FREQUENCY=100METHOD=101SDAMPING=6DISPLACEMENT=1STRESS(PRINT,VONMISES)=1SUBCASE1SUBTITLE=LOAD_XDLOAD=11$SUBCASE2SUBTITLE=LOAD_YDLOAD=12$SUBCASE3SUBTITLE=LOAD_ZDLOAD=13$BEGINBULKPARAM,checkel,noPARAM,POST,-1$AnonymousTEMPSET$TEMPD1121.85$AnonymousDLOADSETDLOAD111.1.110$AnonymousLOADSETDLOAD121.1.111$AnonymousLOADSETDLOAD131.1.112$rload110RLOAD111020.0.53$rload111RLOAD111130.0.53$rload112RLOAD111240.0.53$TABLED1const.1TABLED15LINEARLINEAR+00056E4+00056E41.1.1000.1.ENDT$TABDMP13proz.TABDMP16CRIT+00056E7+00056E70.010.0310000.0.03ENDT$AnonymousFREQ1FREQ11001.1.199$METHODCardEIGRL1010.300.0MASS$RESTRAINCARDSPC1800000011234560.0SPC1800000021234560.0SPC1800000031234560.0SPC1800000041234560.0SPC1800000051234560.0SPC1800000061234560.0SPC1800000071234560.0SPC1800000081234560.0SPC1800000091234560.0SPC1800000101234560.0SPC1800000111234560.0SPC1800000121234560.0SPC1800000131234560.0SPC1800000141234560.0SPC1800000151234560.0SPC1800000161234560.0SPC1800000171234560.0SPC1800000181234560.0SPC1800000191234560.0SPC1800000201234560.0SPC1800000211234560.0SPC1800000221234560.0$$$$ZSPCDData$$$SPCD28000000119810.0SPCD28000000219810.0SPCD28000000319810.0SPCD28000000419810.0SPCD28000000519810.0SPCD28000000619810.0SPCD28000000719810.0SPCD28000000819810.0SPCD28000000919810.0SPCD28000001019810.0SPCD28000001119810.0SPCD28000001219810.0SPCD28000001319810.0SPCD28000001419810.0SPCD28000001519810.0SPCD28000001619810.0SPCD28000001719810.0SPCD28000001819810.0SPCD28000001919810.0SPCD28000002019810.0SPCD28000002119810.0SPCD28000002219810.0$$TABLED1cards$$SPCData$$$$YSPCDDataSPCD38000000129810.0SPCD38000000229810.0SPCD38000000329810.0SPCD38000000429810.0SPCD38000000529810.0SPCD38000000629810.0SPCD38000000729810.0SPCD38000000829810.0SPCD38000000929810.0SPCD38000001029810.0SPCD38000001129810.0SPCD38000001229810.0SPCD38000001329810.0SPCD38000001429810.0SPCD38000001529810.0SPCD38000001629810.0SPCD380000017