基于Optistruct的FSEC赛车电池箱轻量化结构设计及优化

Lightweight Structural Design and Optimization of FSEC Racing Battery Box Based on Optistruct

在中国大学生电动方程式汽车大赛(FSEC)中,整车的轻量化设计对于赛车性能的提高具有十分重要的意义。基于有限元法和Optistruct复合材料多层次优化设计方法,采用碳纤维代替传统钢材对电池箱进行轻量化结构设计及优化。通过自由尺寸优化确定加筋的位置、数量,通过尺寸优化获得各铺层的厚度,通过铺层次序优化获得具体的铺层次序。综合运用加筋结构与夹层结构,非加筋部分采用夹层架构,选用铝蜂窝填充以提高电池箱的防火性能。经优化后的电池箱质量减轻了69.08%。在3种不同加载条件下,箱体的最大位移分别减小了72.74%、70.41%以及82.46%。

In the Chinese University Student Electric Formula Car Competition(FSEC),the lightweight design of the vehicle had great significance for the improvement of the performance of the racing car.Based on the finite element method and the multi-level optimization design method of Optistruct composite material,the carbon fiber was used to replace the traditional steel to design and optimize the structure of the battery box.The position and quantity of the reinforcement were determined by free size optimization,the thickness of each layer was obtained by size optimization,and the order of layup was obtained by ply-stacking optimization.The stiffened wall structure and the sandwich structure were comprehensively used,the unstiffened area adopted a sandwich structure,and the aluminum honeycomb core was used to improve the fire resistance of the battery box.The mass of battery box had been reduced by 69.08%after optimization.Under the three different loading conditions,the maximum displacement of the box was reduced by 72.74%,70.41%and 82.46%,respectively.