Virtual and Physical Prototyping in Mechanical Shock Test of an EV Battery Module

This study presents a methodology used in the design certification of a battery module for electric vehicle applications. The methodology combines virtual and physical techniques to assess the structure under mechanical shock testing, according to the standards’ requirements. Virtual prototyping is used to quantify parameters as stresses and deformations. Performed simulations using the virtual prototype are validated by testing the physical prototype, which allows for assessing various design parameters with a high level of confidence. The testing of a physical prototype is performed using specialized equipment—a mechanical shock test bench—which is developed and manufactured especially for this task. The presented methodology is demonstrated in an industrial use case, and the main contribution of this study is related to the way the combination of virtual and physical prototyping and testing is used.