A comprehensive review of vibration analysis, structural integrity assessment, and vibration mitigation strategies for electric vehicle battery enclosures

Abstract

The increasing adoption of electric vehicles (EVs) has created new challenges for battery systems exposed to continuous vibration, mechanical shocks, and long-term cyclic loading. Battery enclosures play a critical role in protecting cells and modules while maintaining structural integrity, thermal compatibility, sealing performance, and crash safety. This review examines the effects of vibration on EV battery enclosures and summarizes current approaches for structural analysis, durability assessment, and performance improvement. The reviewed methods include analytical approaches, experimental modal testing, finite element analysis, harmonic response analysis, and random vibration fatigue evaluation. The influence of material selection, structural configuration, and damping strategies on enclosure performance is discussed, with particular attention to lightweight solutions such as aluminum foam sandwich structures. In addition, recent developments in intelligent monitoring approaches, including digital twins, smart sensing, and data-driven techniques, are reviewed. The findings highlight the importance of integrating structural design, material engineering, and advanced monitoring methods to improve the reliability and durability of future EV battery enclosure systems.