电动轿车车门多工况轻量化设计

Light-weight Design for Electric Vehicle Door Based on Multi-working Conditions

针对某电动轿车的铝合金车门,建立了有限元模型,对车门进行了模态分析以及4种较恶劣工况下的刚度分析,提出了一种基于拓扑优化、尺寸优化及多工况同步优化的综合优化方法。以车门重量最小化为目标,建立了优化模型,并对车门结构进行了轻量化设计。结果表明:该方法能准确寻找车门结构性能的薄弱区域,优化后4种工况下车门刚度提高67%~73%,重量仅增加5%。

The finite element model for the aluminum alloy door of an electric vehicle was established. The modal analysis for the door was carried out. The stiffness of the door under 4 harsh conditions was also analyzed. A comprehensive optimization method which was based on the topology optimization,the size optimization and simultaneous optimization for multi-working conditions was proposed. An optimization for the aluminum alloy door was completed to identify the effectiveness of the proposed method. The results show that the weak areas of the door can be found with the present comprehensive optimization method considering the multi-working conditions of Electric Vehicle Door. The stiffness of the door under the 4 working-conditions is increased to 67% ~ 73%,while only little mass is increased for the door. That means that the aim of the light-weight for the door is achieved.