基于正交试验的电动汽车电池箱结构优化

Structure Optimization of Electric Vehicle Battery Box Based on Orthogonal Experiment

电动汽车电池箱设计生产保守,存在质量笨重、结构设计不合理等缺陷。以某型号电动汽车电池箱为研究对象,建立原电池箱有限元模型,分析在颠簸路面的极限工况下的应力和应变。根据第四强度理论,原电池箱节点最大应力值远小于材料屈服极限,原始结构整体有优化设计的余量。基于正交试验设计,考查了材料类型、加强筋形式、材料厚度三因素对电池箱应力、应变、模态与质量的影响。分析研究了多指标因素不同水平下,影响电池箱应力、应变、模态与质量变化及其分布规律。采用综合平衡分析法确定了最优电池箱结构形式,即材料类型采用5052-H32,加强筋形式为纵向布置,材料厚度2.0mm。对最优组合进行数值模拟,电池箱的应力得到了提高,质量减少了65.85%。分析结果表明:进行此优化设计电池箱的综合性能有所提高,有效减轻了电池箱重量,为以后电池箱的设计提供了指导。

The battery box of electric vehicle production followthe principle of conservatism,which caused great weight and unreasonable structure design. For the battery box of a certain type of electric vehicle,a finite element model of the original battery box was established,the stress and strain were analyzed at the extreme conditions of the bumpy road. According to the fourth strength theory,the maximum stress value of the primary battery box is far less than the yield limit of the material,and the original structure can be optimized. Based on orthogonal design,the influences of the material type,the reinforcement form and the material thickness on the stress,strain,mode and quality of the battery box were examined. Furthermore,their impact regulations under different levels of the multi-index factors were analyzed. The optimal battery box structure form is ultimately determined,namely,the material type is 5052-H32,the reinforcement form is arranged in the longitudinal direction,and the material thickness is 2. 0 mm. The optimal combination is simulated numerically. The stress of the battery box was improved and the quality was reduced by 65. 85%. Analysis results showthat,the overall performance of the optimized battery box is improved,the weight of the optimized box is reduced effectively,providing reference for future structural design of battery box.