Battery packs in BEVs are multidisciplinary design challenges balancing cost, weight, volume, range, and charging time. As the heaviest and most expensive component, their reliability and safety under vibration and shock is critical. This contribution presents an indicator to cluster measured vibration data of BEV battery packs based on coupling with the car body, enabling identification of representative designs and generalization of vibration behavior for future, more integrated architectures.

The modeling of battery electric vehicles (BEVs) still represents a challenge for vehicle manufacturers. The installation of the new types of components needed for BEVs gives rise to uncertainties in the quantification of parameters like the vehicle's weight. Indeed, vehicle weight plays a key role, since it has a drastic effect on the vehicle's range, which is an important selling point for BEVs. Uncertainties in weight estimation create weight fluctuations during the early development phase and the need to resize components like the electric machine or battery. This in turn affects the components' volume and weight. However, such resizing can also lead to component collision and unfeasibility of the vehicle architecture. To solve this problem and to support concept engineers during the early development phase, an iterative approach is required that is capable of estimating weight and volume fluctuations in the relevant components. The approach should also consider the geometrical interdependencies of the components, to ensure that no collisions occur between them. Taking the gearbox as an example application, this paper presents a novel approach that satisfies these requirements.