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Crash modeling of high-voltage cable connectors in electric vehicles

Abstract : Electric vehicles have to comply with several safety regulations. This includes risks of electrical and fire hazards due to the damage of high-voltage connectors in road traffic accidents. In order to validate high-voltage (HV) connector protection, a reliable numerical model is required for full-scale crash simulations. This numerical model must reproduce efficiently (accurately within a reasonable CPU time) the physical response of the HV connector during a crash. HV connectors used in electric vehicles have a complex geometry and they are made of the assembly of hybrid multi-materials. Therefore, their accurate modeling necessitates the use of three-dimensional finite element mesh with complex nonlinear material models including contact with friction. Unfortunately, this standard modeling leads to a significant cost in CPU time and therefore is incompatible with the automotive industry requirements for a full-vehicle crash simulation. This thesis presents a new methodology for the development of surrogate numerical models of HV connectors specific for electric vehicles. The resulting surrogate model is based on the use of basic surface features to define the appropriate suitable geometry which will be modeled using shell elements, together with a functionally graded material model to assess the global response. Once the geometry of the surrogate HV connector is generated, most sensitive physical and material parameters are then identified based on experimental measurements. The generalized incremental stress state dependent damage model is implemented under the assumption of plane stress state condition as a UMAT within LS-DYNA explicit software in order to predict the connector failure initiation. The resulting surrogate HV connector model has been validated, by comparison of its solution to those obtained using a standard three-dimensional fine mesh modeling, as well as component and full vehicle crash experiments at Mercedes-Benz Company. The obtained results, including the accurate prediction of the global mechanical response as well as the connectors failure initiation, in a limited computing time and resources, demonstrates the effectiveness of the proposed methodology.
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Contributor : Frédéric Pruvost Connect in order to contact the contributor
Submitted on : Thursday, March 3, 2022 - 1:37:26 PM
Last modification on : Friday, March 4, 2022 - 3:31:42 AM


Distributed under a Creative Commons Attribution 4.0 International License


  • HAL Id : tel-03595840, version 1


Mohamed Sadok Ridene. Crash modeling of high-voltage cable connectors in electric vehicles. Mechanics []. Université Polytechnique Hauts-de-France; Institut national des sciences appliquées Hauts-de-France, 2022. English. ⟨NNT : 2022UPHF0002⟩. ⟨tel-03595840⟩



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