Enhancing mechanical reliability and safety performance of a battery pack system for electric vehicles: A review

In electric vehicles (EVs), battery packs (BPs) are susceptible to mechanical and functional failures, where various environmental factors are influenced. Although standard testing procedures contribute to improved safety and overall performance, current research primarily examines individual factors, neglecting a comprehensive assessment of battery pack (BP) design solutions. This review comprehensively analyzes safety standards, empirical research, and advances in patent design to provide a broad perspective on the safety of battery pack systems (BPS). Specifically, it examines the responses of BPs to severe environmental conditions, including vibrations, mechanical shock, and collisions. The paper presents comprehensive design solutions, providing valuable knowledge on reducing the likelihood of failure and addressing safety concerns. The review emphasizes the importance of a complete optimization strategy for BPS, explicitly focusing on analyzing mechanical reactions, particularly concerning the reliability and efficacy of safety alerts. The conclusion highlights the imperative to meet operational requirements and safety standards in the design of BP, emphasizing the importance of adopting a robust structural design approach. The study suggested adopting harmonized standards for testing in realistic scenarios. Furthermore, this study makes an innovative contribution by exploring advanced technologies, such as FEA-DNN, reinforcement learning, and various intelligent optimization algorithms, to mitigate mechanical stresses, vibrations, shock impacts, and collision-induced damage in different work environments, providing engineering guidance to enhance the safety performance of BPS.