Structural Safety Performance Simulation Analysis of a Certain Electric Vehicle Battery Pack Based on Multi-Working-Condition Safety Evaluation

This study takes the power battery pack of a pure electric vehicle as the research object, focusing on safety—a core concern widely emphasized in the automotive industry. In practical application scenarios, evaluating the safety of the power battery pack through a single operating condition fails to fully reflect its comprehensive safety performance throughout the vehicle’s entire life cycle. To overcome this limitation, a systematic analysis process was established. First, Catia geometric modeling software was used to simplify the battery pack structure, and HyperMesh was then employed for mesh generation. Second, three core analyses were conducted: static analysis, modal analysis, and extrusion condition analysis. A multi-condition safety evaluation system for electric vehicle battery packs during computer simulation analysis was proposed, which evaluates the battery pack from three dimensions: “dynamic stiffness-static strength-extrusion safety”. Results show that: modal analysis reveals the battery pack’s low-order natural frequencies exceed the vehicle’s excitation frequency (excitation point on the case cover); static analysis confirms it meets operational requirements; extrusion verification proves its safety complies with new national standards. The coupling effect of this multi-dimensional analysis breaks through the limitations of safety performance evaluation under a single operating condition, more realistically reflecting the battery pack’s comprehensive safety over its life cycle and providing a more systematic basis for power battery pack optimization.