The Research On Several Key Technologies Of Electric Vehicles Crash Safety

With the promotion and use of electric vehicles, the security issues of electric vehicles become the attention focus inside and outside the industry. Compared to traditional fuel vehicles, electric vehicles have its own particularity in crash safety. Heavier than traditional cars, for the battery power system, when EVs’crash happens people maybe get more injure. So it is significant to study EVs’crash security for developing and popularizing electric vehicles.Crash safety of two types of electric vehicles is studied in this paper. Firstly, the electric vehicle modified from traditional fuel vehicles is studied. By analyzing front crash simulation results, both its battery acceleration and firewall intrusion exceed the secure range. Then the optimal design scheme is reached by five rounds’optimization and design. Crash safety of the first type electric car can be improved significantly by adding triangular structure between the bumper and battery and applying hot forming material to longitudinal frame instead of ordinary steel.Secondly, the second type electric vehicle specifically designed for electric driving is researched. The EV’s simulation and test results match well in Full Front Barrier (FFB) test and Offset Deformable Barrier (ODB) crash. It’s shown both EV’s acceleration and intrusions of steering column and pedal groups meet the design requirements. Also, the key energy-absorbing components are deformed reasonably and the battery deformation is very small for not being hit directly. However, the bumper and crash can are torn, which occurred in non-collision side in ODB. For that, the sled test subsystem is designed. And the sled model is built based on EV’s model. Then the sled test is conducted, and the effective correlation of the EV and sled is verified through analyzing the EV crash and the sled test results. As a result, the sled test provides a method for optimizing the bumper structure efficiently with low cost.Simultaneously the potential risks in FFB and ODB crash for front cabin high-voltage lines are analyzed. And then two solution schemes are put forward to avoid such high-voltage lines’problems as leakage, short circuit and other hazardous phenomena in the EV crash.