Research On Lightweight Design And Optimization Of Electric Vehicle Power Battery Pack

Lightweight is an everlasting topic in automobile industry.Besides policy orientation,lightweight is also of great significance to energy consumption rate and product performance improvement.Under this background,the feasibility of aluminum alloy profile as the lightweight direction of power battery pack material is discussed in this paper,taking the electric vehicle battery pack as the research point and aluminum profile as the material.The main contents and conclusions are as follows:Firstly,according to the design index of the vehicle,the work including the core,the selection of the key components and the structure design of the power battery box is completed,the preliminary scheme of the power battery system is formed,and the design of the digital-analog structure is completed.According to the finite element theory,the finite element model of the power battery system is established.In order to facilitate the calculation of the subsequent finite element model,the complex module is simplified as the Young’s modulus body.The modal and strength of the finite element model are analyzed,the modal and strength of the model are far higher than the required value,and the structure is optimized according to the results of the analysis,and the optimized model is formed.Secondly,according to the static and fatigue analysis theory of finite element,taking the power battery system as the research object,based on the Abaqus software,the strength,mode,extrusion and collision analysis of the lightweight power battery are carried out.The vibration fatigue simulation of battery system is analyzed based on Ncode software.The results show that the Y-direction extrusion properties and vibration fatigue life are at risk of meeting the standards required by GB/T 31467.3 code.The results show that Y-direction maximum plastic deformation is reduced from 249%to 14.3%by changing the lap-lap relationship and power-down structure.The results show that Y-direction maximum plastic deformation is reduced from 249%to 14.3%.Aiming at the vibration fatigue performance,the structural adhesive is added to the lower part of the module for optimization,simulation verification is carried out after optimization,and the Z-direction fatigue life is increased from 1.829×10~2to 2.068×10~7larger than the target value 2×10~5,and the fatigue life index is adopted;Finally,the sample package is made according to the final design scheme,and the sample package is tested according to the standard test standard.After Z,Y,X,the battery pack has no damage,insulation resistance and capacity are not attenuated after high frequency vibration of the three directions of 21h.The battery pack carries out X,Y two directions,and the battery system has no leakage and ignition.After the collision test,the battery system has no obvious deformation and damage,and the vehicle passes the collision test.Through the research work,the aluminum alloy profile is applied to the battery pack,Through reasonable optimization design,the power battery system pack is reduced by more than 30%.