Abstract:

A topology design space was established based on the physical dimensions to find a new integrated engineering solution considering different subsystems (body-in-white, chassis and battery structure) for meeting the performance requirements of an electrical vehicle (EV). Compound effects of static and dynamic load were investigated through equivalent static load (ESL) method in density-based topology. Minimum weighted strain energy was defined as the topology optimization objective. The key load path of the EV was find out through interpretation of the topology optimization results. And also the load path was validated in computer aided engineering (CAE) model. The result shows that the vehicle global torsion stiffness and modal of battery in the vehicle can satisfy the requirements, and the battery frame does not deform obviously under 32 km/h side rigid pole impact analysis. The architecture load path of the EV satisfies the requirements of the whole vehicle package and performance and local performance of battery. The integration design is also the optimal and lightweight solution.

Key words: electrical vehicle (EV) , advanced architecture ,  integration design , topology optimization ,  equivalent , static loads (ESL)