Influences on Vibration Load Testing Levels for BEV Automotive Battery Packs

Battery Electric Vehicles (BEVs) have an increasingly large share of the vehicle market. To ensure a safe and long operation of the mostly large underfloor-mounted traction batteries, they must be developed and tested in advance under realistic conditions. Current standards often do not provide sufficiently realistic requirements for environmental and lifetime testing, as these are mostly based on data measured on cars with an Internal Combustion Engine (ICE). Prior to this work, vibration measurements were performed on two battery-powered electric vehicles and a battery-powered commercial mini truck over various road surfaces and other influences. The measurement data are statistically evaluated so that a statement can be made about the influence of various parameters on the vibrations measured at the battery pack housing and the scatter of the influencing parameters. By creating a load profile based on the existing measurement data, current standards can be questioned and new insights gained in the development of a vibration profile for the realistic testing of battery packs for BEVs.