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International Research Journal of Engineering and Technology (IRJET)

e-ISSN: 2395-0056

Volume: 10 Issue: 05 | May 2023

p-ISSN: 2395-0072

www.irjet.net

Design and Analysis of Electric Vehicle Battery Fixture Prasad Nemane1, Pranav Mane2, Rahul Karmoda3, Prakash Adballe4, Dr. P.T. Nitnaware5 1,2,3,4,5Mechanical Engineering Department, D. Y. Patil College of Engineering Akurdi, Pune 411-044

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Abstract – This research paper focusses on design of

As a result, aluminum is a superior material for highfrequency vibration fixtures.

electric vehicle battery vibration testing fixture which will capable of withstanding random vibration loads as per AIS 156 standards. The process involves selecting appropriate material and fixture configurations, creating CAD model and using Finite element analysis to find out natural frequencies and mode shapes. To validate the design, the fixture is tested experimentally using FFT analyzer. The experimental results are compared to the Finite Element results to conclude the fixture's suitability for testing four-wheeler env 200 battery pack.

2. DESIGN OF FIXTURE The 3D Model of fixture is drafted using CATIA V5 software. The dimensions of fixture chosen from the env200 mountings and shaker table hole to hole distance. The dimensions are as follows: 1. Base plate hole radius= 5 mm 2. Base plate length= 1300 mm 3. Base plate breadth= 1400 mm 4. Base plate height= 5 mm 5. Overall width of fixture= 325 mm 6. Overall length of fixture= 400 mm 7. Square channel thickness= 2 mm 8. Square channel size= 25×25 mm 9. Highest support member height = 40 mm 10. Shortest support member height= 25 mm 11. Base plate hole centre to centre= 100 mm

Key Words: E-Vehicle, Battery Vibration Testing, Fixture Design, Modal Analysis, Natural Frequency, FFT Analyzer

1. INTRODUCTION The testing machines available for testing components in real life do have some limitations. They have a restricted area for mountings. These vibration components are unable to mount directly on the respective machine. So, we need to design such fixtures which can hold the component and can be mounted on the testing machine, so that the testing can be carried out to find out the best possible results. Moreover, the fixture should also be capable of sustain those vibrations without its own fatigue failure under repeated vibrational disturbance.

1.1 Objectives 1. 2. 3. 4. 5.

Selection of appropriate material for the fixture. Design a Fixture for Electric four-wheeler battery using Catia V5 FEA analysis of Fixture by using ANSYS Workbench 19. Manufacturing the fixture Experimental validation of battery fixture by using FFT Analyzer.

Fig. 1 Fixture and Base Plate Design Assembly The env200 battery model:

1.2 Material Selection We have three options in materials. Magnesium has high tensile strength to weight ratio but it is not easy to machine and also costlier. steel and aluminum have similar strength-to-weight properties, it may be more cost-effective to select steel due to its lower cost. However, aluminum has a significantly lower density than steel, allowing for the creation of larger and stiffer features without adding weight.

Impact Factor value: 8.226

Fig. 2 Env200 Baterry Mockup

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