纯电动汽车轻量化机舱支架总成优化与验证

Optimization and Verification of the Lightweight Engine Room Bracket of Electrical Vehicle

为了满足纯电动汽车轻量化的需求,针对长安某纯电动汽车结构功能件机舱支架总成进行了复合材料轻量化开发,基于性能及成本因素选用了片状模塑料(sheet molding compound,SMC),对该SMC机舱支架总成进行了CAE分析及台架疲劳振动试验,根据试验分析结果进行了分析模型及结构优化,并对优化后的SMC机舱支架总成进行了试验验证。研究结果表明,悬挂重量对复合材料机舱支架总成的性能有较大影响,CAE建模应体现悬挂重量,分析模型及结构改进后的SMC机舱支架总成可以满足强度及疲劳耐久要求;相对于金属机舱支架总成,SMC部件可以实现2 kg,减重率为31.3%,轻量化效果明显,SMC部件成本相对于金属部件成本只增加20元,每公斤减重的成本为10元,成本增加可以接受,具有大批量应用前景;应用SMC复合材料,可以大量减少生产工序,取消焊接流程,能够明显降低能源消耗,同时降低了排放和资源消耗,符合国家节能环保政策,为纯电动车及汽车结构功能件轻量化开发提供了一个很好的方向。

In order to meet the lightweight requirements of pure electric vehicles,a compound material lightweight development was carried out for the engine room support assembly of a pure electric vehicle of Chang an.Sheet molding compound(SMC)was selected based on performance and cost factors,and CAE analysis and bench fatigue vibration test were carried out for the SMC engine room support assembly.According to the test analysis results,the analysis model and structure optimization were carried out,and the optimized SMC nacelle support assembly was verified by test.Research results show that the suspension weight has a great impact on the performance of the composite engine room support assembly,and CAE modeling should reflect the suspension weight.The analysis model and the improved SMC engine room support assembly can meet the requirements of strength and fatigue durability.Compared with the metal engine room bracket assembly,SMC component can achieve a 2kg weight reduction with a weight reduction rate of 31.3%,whose lightweight effect is obvious.Compared with the cost of metal parts,the cost of SMC components only increases by 20 yuan,and the cost of weight reduction per kilogram is 10 yuan.The cost increase is acceptable and has the prospect of mass application.The application of SMC composite materials can greatly reduce the production process,cancel the welding process and significantly reduce the energy consumption.At the same time,it reduces emissions and resource consumption.It conforms to the national energy conservation and environmental protection policy and provides a good direction for the lightweight development of pure electric vehicles and automotive structural functional parts.