Rama, M Farrel Baihaqi (2026) Desain Dan Analisa Crashworthiness Pada Struktur Battery Pack Mobil Listrik Dengan Variasi Struktur Frame Menggunakan Explicit Dynamic Analysis. Masters thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
Struktur battery pack merupakan komponen keselamatan utama pada kendaraan listrik yang berfungsi melindungi sel baterai dari beban mekanik dan benturan akibat kecelakaan. Kegagalan struktur battery pack dapat menyebabkan kerusakan sel baterai yang berpotensi memicu thermal runaway, sehingga diperlukan desain struktur dengan kemampuan crashworthiness yang baik. Penelitian ini bertujuan menganalisis pengaruh variasi geometri frame terhadap performa crashworthiness struktur battery pack serta menentukan konfigurasi frame yang paling optimal. Variasi geometri yang dianalisis meliputi frame silinder, segitiga, dan setengah lingkaran menggunakan metode Explicit Dynamic Analysis berbasis Finite Element Method (FEM) pada perangkat lunak ANSYS 2023 R1. Simulasi dilakukan menggunakan impaktor dengan kecepatan 10 m/s yang mengacu pada standar vehicle crash test, dengan energi impak awal sebesar 7000 J serta pembebanan dari arah samping (sumbu X) dan depan (sumbu Z). Parameter yang dianalisis meliputi tegangan von Mises, deformasi total, internal energy, Initial Peak Force (IPF), Mean Crushing Force (MCF), dan Crash Force Efficiency (CFE). Hasil simulasi menunjukkan bahwa variasi geometri frame memberikan pengaruh yang signifikan terhadap respons mekanik struktur battery pack. Frame segitiga menghasilkan tegangan maksimum tertinggi hingga 268,8 MPa, sedangkan frame silinder menunjukkan tegangan maksimum sebesar 201,5 MPa. Frame setengah lingkaran menghasilkan tegangan maksimum terendah, yaitu 164,4 MPa pada pembebanan arah X dan 189,5 MPa pada arah Z, serta rasio penyerapan energi tertinggi mencapai 73,14% pada arah X dan 72,14% pada arah Z. Meskipun frame setengah lingkaran menghasilkan deformasi terbesar dibandingkan variasi lainnya, seluruh variasi masih memiliki deformasi maksimum yang berada di bawah batas clearance sebesar 30 mm, sehingga seluruh desain memenuhi kriteria keselamatan yang digunakan dalam penelitian ini. Geometri setengah lingkaran mampu mendistribusikan beban impak secara lebih merata ke seluruh struktur sehingga menghasilkan distribusi tegangan yang lebih homogen, kemampuan disipasi energi yang lebih baik, dan karakteristik gaya penghancuran yang lebih stabil. Dengan demikian, frame setengah lingkaran direkomendasikan sebagai konfigurasi struktur battery pack yang paling optimal karena memberikan keseimbangan terbaik antara perlindungan modul baterai, distribusi beban, dan kemampuan penyerapan energi selama proses tumbukan.
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The battery pack structure is a critical safety component in electric vehicles that protects battery cells from mechanical loads and impact forces during vehicle collisions. Failure of the battery pack structure may cause battery cell damage, potentially leading to thermal runaway. Therefore, improving the crashworthiness performance of the battery pack through structural optimization is essential. This study aims to investigate the effect of frame geometry on the crashworthiness performance of an electric vehicle battery pack structure and to determine the optimum frame configuration. Three frame geometries, namely cylindrical, triangular, and semi-circular, were evaluated using Explicit Dynamic Analysis based on the Finite Element Method (FEM) in ANSYS 2023 R1. Impact simulations were performed using an impactor velocity of 10 m/s, following the vehicle crash test loading condition, with an initial impact energy of 7000 J. Two loading directions were considered, namely lateral (X-axis) and frontal (Z-axis). The evaluated crashworthiness parameters included von Mises stress, total deformation, internal energy absorption, Initial Peak Force (IPF), Mean Crushing Force (MCF), and Crash Force Efficiency (CFE). The simulation results demonstrate that frame geometry has a significant influence on the mechanical response of the battery pack structure. The triangular frame produced the highest maximum von Mises stress of 268.8 MPa, while the cylindrical frame exhibited an intermediate maximum stress of 201.5 MPa. The semi-circular frame achieved the lowest maximum stress values of 164.4 MPa under lateral loading and 189.5 MPa under frontal loading, together with the highest energy absorption ratios of 73.14% and 72.14%, respectively. Although the semi-circular frame experienced the largest deformation among all configurations, the maximum deformation of every design remained below the 30 mm clearance, indicating that all frame configurations satisfied the safety criterion adopted in this study. The continuous curvature of the semi-circular geometry enabled a more uniform distribution of impact loads throughout the structure, resulting in a more homogeneous stress distribution, improved energy dissipation, and more stable crushing behaviour. Therefore, the semi-circular frame is recommended as the optimum battery pack frame configuration because it provides the best balance between battery module protection, impact load distribution, and energy absorption capability during collision events.
| Item Type: | Thesis (Masters) |
|---|---|
| Uncontrolled Keywords: | Battery pack. Electric vehicle, FEM, Crashworthiness, Explicit Dynamic analysis. |
| Subjects: | T Technology > TL Motor vehicles. Aeronautics. Astronautics > TL220 Electric vehicles and their batteries, etc. |
| Divisions: | Faculty of Industrial Technology and Systems Engineering (INDSYS) > Mechanical Engineering > 21101-(S2) Master Thesis |
| Depositing User: | M Farrel Baihaqi Rama |
| Date Deposited: | 30 Jul 2026 02:31 |
| Last Modified: | 30 Jul 2026 02:31 |
| URI: | http://repository.its.ac.id/id/eprint/140240 |
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