Virtual Detection of Mechanically Induced Short Circuits in a Cylindrical Lithium-Ion Battery Cell Based on Finite Element Simulation

Lithium-ion batteries (LIBs) are commonly used in today’s electric vehicles. Studying their behaviour under mechanical loading, including short circuits, is vital for vehicle safety. This paper covers three major topics, (1) a general literature review for the state-of-the-art of LIBs, (2) physical cell tests for model validation are performed, wherein the occurrence of short circuits is detected and (3) creating a finite element model (FEM) of an 18650 cylindrical LIB using the most recent testing and simulation techniques. A variety of short-circuit criteria based on stresses, strains and geometric parameters have been implemented in the simulation and compared to the test results. It will be demonstrated that a combination of two geometric criteria, in the radial and axial directions of the cell, is best suited for virtual short-circuit detection in the simulation. Finally, the short-circuit criteria are implemented in a post-processing tool that allows fast short-circuit analysis of cells of different loadings. In the future, this method of short-circuit detection will be used to analyse an assembly of several battery cells such as, for instance, an automotive or maritime battery pack. Furthermore, the developed method enables mechanical integration with respect to crash safety in vehicles.