Aerodynamic drag optimization design of a commercial battery electric pickup truck

doi:10.3969/j.issn.1674-8484.2025.06.009

Abstract

Abstract:

A modular optimization scheme for aerodynamic components was proposed to enhance the performance of a commercial pure electric pickup truck built on a traditional fuel vehicle platform. The research combined computational fluid dynamics (CFD) simulation, wind tunnel testing, and coast-down testing to analyze, optimize, and validate the vehicle's aerodynamic performance. The simulations using STAR-CCM+ software identified an excessively high front face, an uneven underbody, and poor sealing to be the three major sources of aerodynamic drag. The investigation focused on eight key components, including the front air dam, side steps, and roof rack, to examine their aerodynamic effects and drag reduction mechanisms. The results indicate that the optimized design reduces the drag coefficient (C_d) by 21.06% in CFD simulations and by 20.6% in wind tunnel tests. The deviation of less than 3% between these values confirms the reliability of the CFD model. Coast-down tests further demonstrates a 6.3% increase in driving range. This work provides practical engineering methodologies and experimental evidence for the aerodynamic development of commercial “fuel-to-electric” converted pickup trucks.

Key words: electric pickup truck, aerodynamic drag, air dam, side steps, roof rack, wind tunnel

CLC Number:

U461.1

CHEN Chunju, LI Xiaohua, YU Xianzhong, QI Qi, ZOU Jiayi. Aerodynamic drag optimization design of a commercial battery electric pickup truck[J]. Journal of Automotive Safety and Energy, 2025, 16(6): 896-904.

Figures/Tables 16

References 18

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单圆管货架位置/ mm	ΔC_d降幅%	ΔA / m²
蓝色Base货架	0.37	0
X后移20	0.55	0
X后移40	0.37	0
X后移60	0.18	0
Z上移10	0.37	0
Z上移20	0.55	0
Z上移30	0.37	5×10^-4
Z上移50	0.00	1×10^-3
X后移20，Z上移20	0.74	0

单圆管货架位置/ mm	ΔC_d降幅%	ΔA / m²
蓝色Base货架	0.37	0
X后移20	0.55	0
X后移40	0.37	0
X后移60	0.18	0
Z上移10	0.37	0
Z上移20	0.55	0
Z上移30	0.37	5×10^-4
Z上移50	0.00	1×10^-3
X后移20，Z上移20	0.74	0

方案	整车C_d		仿真和试验差异/ %
方案	仿真	风洞试验	仿真和试验差异/ %
Base	1.000 0	1.008 8	0.87
前保气坝	0.885 0	0.902 4	1.93
冷却密封	0.873 2	0.889 2	1.79
底盘下护板	0.855 6	0.874 5	2.16
电池包护板	0.840 9	0.856 9	1.86
侧踏板	0.826 2	0.840 7	1.72
货箱密封	0.811 5	0.826 0	1.75
卷帘式货箱盖	0.796 8	0.808 4	1.43
货架	0.789 4	0.801 0	1.44
降阻合计	0.210 6	0.207 8	-

方案	整车C_d		仿真和试验差异/ %
方案	仿真	风洞试验	仿真和试验差异/ %
Base	1.000 0	1.008 8	0.87
前保气坝	0.885 0	0.902 4	1.93
冷却密封	0.873 2	0.889 2	1.79
底盘下护板	0.855 6	0.874 5	2.16
电池包护板	0.840 9	0.856 9	1.86
侧踏板	0.826 2	0.840 7	1.72
货箱密封	0.811 5	0.826 0	1.75
卷帘式货箱盖	0.796 8	0.808 4	1.43
货架	0.789 4	0.801 0	1.44
降阻合计	0.210 6	0.207 8	-