Structure Design And Analysis Of Electric Vehicle Fiber Composite Battery Pack Enclosure

In this paper,starting from the background of new energy and light weight of automobiles,in order to solve the problems of heavy weight,poor corrosion resistance and complicated processing technology of a ZHIDOU miniature electric vehicle battery pack enclosure,using the resin-based fiber reinforced composite materials with low density,high strength,good corrosion resistance and easy forming to redesign the battery pack enclosure.This method not only realizes the lightweight design but also improves the specific energy of the battery pack enclosure and enhances the safety performance of the battery pack enclosure.The research lay the foundation for the design and development of larger and more complex composite battery pack enclosure,and also provide a solution to the electric car to solve the bottleneck of mileage issues in the future.The followings are the main research methods and achievements of this paper.First of all,taking the steel battery pack enclosure as an entry point,from the perspective of the new resin-based fiber composite materials,based on the theory of composite material design,following the principle of battery pack enclosure design,design a new lightweight resin-based composite battery pack enclosure,and use the UG and ANSYS Workbench software to establish the finite element model of the newly designed battery pack enclosure.Secondly,the static characteristic analysis and dynamic characteristic analysis of the composite battery pack enclosure are carried out.In the static finite element analysis,the paper researches the battery pack enclosure in five kinds of classic conditions including vertical bumpy road,left turn,right turn,front brake and reverse brake,draws its maximum stress and maximum deformation of the battery pack enclosure under these five conditions,and the research results do not exceed the allowable range of the battery pack enclosure material.In the modal analysis of the whole battery pack enclosure,obtain the beginning six natural frequencies and corresponding vibration modes of the whole battery pack enclosure structure,getting that resonance phenomenon will not occur.Based on finite element analysis of composite battery pack enclosure,the structural improvement and parameter optimization of the battery pack enclosure are carried out in this paper.After optimization,battery pack enclosure makes a great weight loss,and compared with the original steel battery pack enclosure,light weight effect is significant.The maximum deformation of the upper cover in the case of resonance becomes smaller,and the maximum stress of the battery pack enclosure in the case of vertical bump is greatly reduced.The stress concentrated phenomenon in the ventilation duct of the battery pack enclosure is also removed.Finally,combined with the theory of composite material forming process,use fiber composite materials to complete a battery pack enclosure production,proving that RTM molding process is reliable.Through the experimental study on the composite battery pack enclosure,it proves that the model analysis is right,and the feasibility of application of the resin-based fiber composite in the battery pack enclosure is confirmed.