PSI - Issue 75

Marco Bonato et al. / Procedia Structural Integrity 75 (2025) 719–729 Author name / Structural Integrity Procedia (2025)

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* Corresponding author. Tel.: 0033 1 30 13 51 97 E-mail address: marco.bonato@valeo.com © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the Fatigue Design 2025 organizers Keywords: Vibration, Automotive, Finite Element Analysis, Simulation, Fatigue, Reliability © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under the responsibility of Dr Fabien Lefebvre with at least 2 reviewers per paper

Nomenclature b

Basquin’s Fatigue Exponent Battery Electric Vehicles Electrical Driven Compressor Finite Element Analysis Fatigue Damage Spectrum Internal Combustion Engine Printed Circuit Board Power Spectrum Density

BEV eDC FEA FDS ICE PCB PSD PoF

Physics-of-Failuire

Q Quality Factor i: damping ratio 1. Introduction i:

Reliability of the component is a key element for the success of battery electric vehicles. In particular, those parts involved in the thermal management of the car need to guarantee optimum working parameters in order to optimize the energy consumption. Unlike traditional internal combustion engine (ICE) vehicles, where waste heat can be used for cabin heating, EVs rely primarily on electric heating systems. These systems often utilize a heat pump, which is essentially a refrigerator operating in reverse, using a compressor to move heat from the outside air or battery to the cabin. A malfunctioning compressor in an EV can significantly impact passenger comfort, especially in cold climates, and can also reduce the vehicle's range due to increased energy consumption for heating. Therefore, robust validation and mitigation of vibration-related failure modes are crucial for ensuring the reliability and durability of compressors in EVs. Modern BEV carries an electrical driven compressor (eDC). This product is a complex mechatronic component, combining both mechanical parts (the scroll, the housing, the pressure valves) and electric ones (the electric motor, the inverter etc.). Validation of a compressor involves ensuring it meets the required performance and reliability standards. This typically includes tests for: ● Performance: Evaluating parameters like pressure ratio, flow rate, efficiency, and power consumption under various operating conditions. ● Durability and Reliability: Assessing the compressor's ability to withstand continuous operation, thermal cycling, vibration, and other environmental stresses. This often involves accelerated life testing and endurance tests. ● Safety: Verifying the compressor's safe operation under various conditions, including overpressure, overtemperature, and other potential hazards.