Development of a Battery Cell Busbar Shape with Concurrent Multi-Functional Performance

Abstract

In the present study, we propose a data-driven set-based design method employing Differential Evolution Based Adaptive Sampling (DEBAS) and explore its application to the Multi-disciplinary Design Optimization (MDO) problem of battery cell straight hat-shaped busbar. Busbars, responsible for electrically interconnecting the multitude of cells in an electric vehicle's battery pack, primarily demand electrothermal performance during energization, assembly performance in the manufacturing welding process, and mechanical strength as key performance attributes, each quantified through respective Computer Aided Engineering (CAE) techniques. A busbar shape that can simultaneously satisfy multiple performance criteria and be integrated into a component unit, known as a busbar module, has been successfully developed.