汽车工程

汽车工程 ›› 2022, Vol. 44 ›› Issue (4): 591-600.doi: 10.19562/j.chinasae.qcgc.2022.04.014

所属专题： 新能源汽车技术-电驱动&能量管理2022年

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新能源汽车高压线束在机械外载下失效试验及仿真研究

赵杨1(),徐小飞2,吴海龙1,葛宇龙1   

  1. 1.清华大学苏州汽车研究院（相城），苏州 215000
    2.上海汽车集团股份有限公司技术中心，上海 201804
  • 收稿日期:2021-08-10 出版日期:2022-04-25 发布日期:2022-04-22
  • 通讯作者: 赵杨 E-mail:zhaoyang@tsari.tsinghua.edu.cn

Failure Test and Simulation Study of New Energy Vehicle HV-Cable Under Mechanical Loading

Yang Zhao1(),Xiaofei Xu2,Hailong Wu1,Yulong Ge1   

  1. 1.Suzhou Automobile Research Institute of Tsinghua University （Xiangcheng），Suzhou 　215000
    2.Shanghai Automotive Group Co LTD Technology Center，Shanghai 　201804
  • Received:2021-08-10 Online:2022-04-25 Published:2022-04-22
  • Contact: Yang Zhao E-mail:zhaoyang@tsari.tsinghua.edu.cn

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摘要：

随着新能源汽车的发展和普及，针对其电池系统碰撞安全研究的重要性日益凸显。高压线束作为新能源汽车高压电气系统的关键零件，研究其在碰撞工况下的电安全性能尤为重要。本文基于电池系统在碰撞工况下其高压线束可能遭受的典型挤压外载，选取直径15.8 mm的线束设计了D5柱面和V60楔面两种工况动静态挤压试验，试验过程中实时监测冲头与线束内部导体之间短路的发生，并对护套、绝缘层、导体3种组份材料进行拉伸、压缩等试验标定相应材料模型。通过线束结构试验和组份材料试验分别标定线束的单组份均质化模型和导体-等效绝缘层双组份模型。研究结果表明：线束在机械载荷下有很强的动态效应，动态下的力学响应升高。线束的短路行为与外载工况、加载速度高度相关。两种高压线束仿真模型利用单元删除来预测线束短路的仿真结果与试验结果基本一致，两种模型均可准确地预测线束在挤压工况下的短路风险。

关键词: 新能源汽车, 高压线束, 动静态挤压, 组份材料试验, 均质化模型, 双组份模型

Abstract:

It is increasingly important to study the collision safety of the battery system with the development and popularization of new energy vehicles. As a key part of the high voltage electrical system of new energy vehicle， it is particularly important to study its electrical safety performance under crash condition of the high voltage harness. Based on the typical extrusion load that the HV-cable of the battery system may suffer under the crash conditions， the harness with a diameter of 15.8 mm is selected to design the dynamic and static compression tests under two working conditions of the D5 cylindrical surface and V60 wedge surface. During the test， real-time monitoring of short circuit between the punch and the internal conductor of the harness is conducted， and the tensile and compression tests are carried out on the three component materials of sheath， insulation layer and conductor to calibrate the corresponding material model. Through the harness structure test and component material test， the one component homogenization model of HV-cable and the two-component model of conductor-equivalent insulation layer are calibrated respectively. The results show that there is a strong dynamic effect of HV-cable under mechanical load， and the dynamic mechanical response increases. The short circuit behavior of HV-cable is highly related to the external loading condition and loading speed. The simulation results of the two HV-cable simulation models using element deletion to predict the cable short circuit are basically consistent with the test results， and the two models can accurately predict the short circuit risk under extrusion condition.

Key words: new energy vehicle, HV-Cable, dynamic and static extrusion, component material test, homogenization model, two components model