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SANDWICH PANEL COMPOSITE BASED LIGHT-WEIGHT STRUCTURE DESIGN FOR RESERVED ENERGY STORAGE SYSTEM (RESS) PROTECTION
Daniel Irawan*, Sigit Puji Santosa, Annisa Jusuf, Poetro Lebdo Sambegoro

Institut Teknologi Bandung (ITB)


Abstract

The research in the electric vehicle requires a safe Reserved Energy Storage System (RESS) that is durable and crashworthy enough to withstand a harsh environment, especially ground impact from stone chips on the road. RESS, which typically uses lithium-ion type battery, is posed to the jeopardy of thermal runaway as an aftermath of intrusion into the cell body. Thermal runaway might happen because the separator between the anode and cathode spoil and fail to keep both from making contact that results in a short circuit. Nowadays, metallic structures have been applied underneath the cells to protect RESS, although not so useful. Not just the extra mass, it cannot hold the impact properly. This research focuses on a composite-based protective layer applying sandwich panel structures for a stiffer layer. Conducted using non-linear finite element analysis with LS-DYNA solver, this research takes multiple design variables into accounts such as layer thickness, topology, and orientation while maintaining the base material of plain weave Carbon Fiber Reinforced Polymer (CFRP). The variables that are set as performance indicators are mainly cell deformation and energy absorbed. Among the two topologies tested, Navy Truss is proven to get along better with composite material than Blast Resistant Adaptive Sandwich (BRAS) model. This occurs since the Navy Truss absorbs energy by undergoing progressive crushing, BRAS structures collapse within the supports. In the Navy Truss itself, various orientations are tested, and it is found that the most effective orientation is [(0/90)2/[(45/-45)/(0/90)]3]s. Compared to the metallic structure, profusely there has been 36 percent mass saving.

Keywords: crashworthiness, sandwich panel, composite, CFRP, NavTruss, BRAS, RESS

Topic: Lightweight Structure

Link: https://ifory.id/abstract/pcLUFKq9yxEB

Conference: The 6th International Conference on Electric Vehicular Technology (ICEVT 2019)

Plain Format | Corresponding Author (Daniel Irawan)

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