A Study Of Electric Vehicle’s Body Skeleton Structure Design Driven By Topology Optimization

As an important direction of the future vehicle development, pure electric vehicleshave been taken seriously by the major car manufacturers. However, owing to the cost andvolume, pure electric vehicle body usually use traditional automobile refitting, which isunable to fully meet the requirements. Starting from the pure electric vehicle’s owncharacteristics, design meeting the requirements of the body can largely increase materialutilization efficiency and reduce the cost.The study used topology optimization-driven design process to design a vehicleframe structure meeting pure electric vehicle load requirements facilitated by the basicdimensions of benchmarking models. Compared with the benchmarking, the study got anrelatively satisfactory result.In the design process, combined with the current electric vehicle’s load conditions,investigated the effect of different power system layout scheme for vehicle axle load andultimately determine the optimal plan. According to the optimal scheme and electricvehicle’s demand of bending and torsion, using the topology optimization, the study gotan optimal spatial structure.From the topology optimization results, we abstracted out an arrangement framescheme by beam element structure. Ergonomics is an important process of car design, thestudy checked the frame model of beam element structure, got a satisfactory model.In the final detail optimization, firstly, got the size requirements of solid circularsection beam by using the size optimization of the model; secondly, translated solid beamsize parameter into the hollow beam parameters by using the mathematical method;thirdly, got the final model which structured by using the optimal wall thickness of hollowbeams; finally, compared the test of new model and benchmarking car, got the body framedesign meeting the requirements.