Parameter optimization of the sill beam section of an electric vehicle under side pole collision condition

doi:10.3969/j.issn.1674-8484.2024.06.002

Abstract

Abstract:

The peak section force (F_max) of battery modules of an electric vehicle exceeded the safety range under side pole collision condition. The parameter optimization of the sill beam section was carried out to improve battery collision safety and achieve weight reduction of the vehicle body. 26 thicknesses or position parameters were selected as optimization variables to reduce F_max and the mass of sill beam. The maximum compression deformation(d_max) and plastic strain(ε_pmax)of battery modules were chosen as constrains. Firstly, the optimal Latin hypercube method was employed to generate samples. A fully connected neural network was established as approximation model based on samples, and the non-dominated sorting genetic algorithms-Ⅱ(NSGA-Ⅱ) was employed for multi-objective optimization. Finally, optimization results were verified through simulation. The results show that the F_max of battery modules is decreased from 21.8 kN to less than 20 kN, indicating safety requirement is eventually satisfied. Meanwhile, the mass of sill beam is reduced by 1.41%~4.02%, which means lightweight design is also achieved. Further analysis shows that d_max and ε_pmax of battery modules are also reduced synchronously in some solutions, which improves battery collision safety comprehensively in the meantime of weight reduction.

Key words: side pole collision, battery safety, approximation model, lightweight, finite element simulation

CLC Number:

RONG Hai, JIANG Jianzhong, YAO Zaiqi, MA Kai. Parameter optimization of the sill beam section of an electric vehicle under side pole collision condition[J]. Journal of Automotive Safety and Energy, 2024, 15(6): 813-820.

Figures/Tables 13

References 20

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	变量
	基础	方案1	方案2	方案3	方案4	方案5	方案6
t1	2.0	2.0	2.0	2.0	1.9	1.9	2.1
t2	3.0	2.9	2.9	2.9	2.8	2.8	3.3
t3	2.0	2.0	1.8	1.9	2.2	2.0	1.8
t4	1.8	1.8	1.9	1.9	1.9	1.8	1.8
t5	5.5	5.0	5.1	5.6	5.0	5.8	5.9
t6	3.0	3.2	3.0	3.1	3.0	3.2	2.9
t7	1.8	1.8	1.9	1.9	2.0	1.8	1.9
t8	6.0	5.7	6.5	5.8	5.7	6.3	6.3
t9	4.5	4.1	4.4	4.2	4.6	4.5	4.1
t10	3.0	2.8	2.9	2.7	2.7	2.9	2.7
t11	5.5	5.4	5.2	5.3	5.2	5.6	5.8
t12	5.5	5.3	5.2	5.2	5.5	5.3	5.4
t13	2.0	1.9	1.9	2.2	2.0	1.9	1.9
t14	1.8	1.9	1.9	1.8	1.8	1.9	1.9
t15	2.0	2.1	1.9	1.8	2.2	1.8	1.9
t16	1.8	2.0	1.9	2.0	2.0	1.8	2.0
t17	2.0	2.1	2.0	2.1	2.0	2.1	2.1
t18	2.0	1.9	1.8	1.8	2.0	1.9	1.9
t19	2.5	2.4	2.7	2.5	2.8	2.6	2.5
t20	3.0	3.1	2.9	2.9	3.1	2.7	2.8
t21	3.0	3.0	2.7	3.1	2.9	2.9	2.8
t22	3.0	3.2	3.1	2.7	3.1	2.9	3.2
s1	0	-0.3	+0.6	-0.7	+0.6	+0.9	-0.3
s2	0	-1.7	+1.9	+2.8	-0.3	-2.2	-1.5
s3	0	+4.2	-2.1	+4.5	-3.5	-0.1	-3.1
s4	0	-0.3	+3.3	+4.0	-0.1	-3.2	+1.9

	变量
	基础	方案1	方案2	方案3	方案4	方案5	方案6
t1	2.0	2.0	2.0	2.0	1.9	1.9	2.1
t2	3.0	2.9	2.9	2.9	2.8	2.8	3.3
t3	2.0	2.0	1.8	1.9	2.2	2.0	1.8
t4	1.8	1.8	1.9	1.9	1.9	1.8	1.8
t5	5.5	5.0	5.1	5.6	5.0	5.8	5.9
t6	3.0	3.2	3.0	3.1	3.0	3.2	2.9
t7	1.8	1.8	1.9	1.9	2.0	1.8	1.9
t8	6.0	5.7	6.5	5.8	5.7	6.3	6.3
t9	4.5	4.1	4.4	4.2	4.6	4.5	4.1
t10	3.0	2.8	2.9	2.7	2.7	2.9	2.7
t11	5.5	5.4	5.2	5.3	5.2	5.6	5.8
t12	5.5	5.3	5.2	5.2	5.5	5.3	5.4
t13	2.0	1.9	1.9	2.2	2.0	1.9	1.9
t14	1.8	1.9	1.9	1.8	1.8	1.9	1.9
t15	2.0	2.1	1.9	1.8	2.2	1.8	1.9
t16	1.8	2.0	1.9	2.0	2.0	1.8	2.0
t17	2.0	2.1	2.0	2.1	2.0	2.1	2.1
t18	2.0	1.9	1.8	1.8	2.0	1.9	1.9
t19	2.5	2.4	2.7	2.5	2.8	2.6	2.5
t20	3.0	3.1	2.9	2.9	3.1	2.7	2.8
t21	3.0	3.0	2.7	3.1	2.9	2.9	2.8
t22	3.0	3.2	3.1	2.7	3.1	2.9	3.2
s1	0	-0.3	+0.6	-0.7	+0.6	+0.9	-0.3
s2	0	-1.7	+1.9	+2.8	-0.3	-2.2	-1.5
s3	0	+4.2	-2.1	+4.5	-3.5	-0.1	-3.1
s4	0	-0.3	+3.3	+4.0	-0.1	-3.2	+1.9

	m / kg	F_max / kN	d_max / mm	ε_pmax
基础	19.14	21.80	4.98	0.32
方案1	18.37	19.54	4.92	0.31
方案2	18.41	19.14	4.43	0.27
方案3	18.67	18.24	4.43	0.29
方案4	18.71	18.13	4.41	0.37
方案5	18.81	18.05	4.16	0.3
方案6	18.87	17.55	3.93	0.38

	m / kg	F_max / kN	d_max / mm	ε_pmax
基础	19.14	21.80	4.98	0.32
方案1	18.37	19.54	4.92	0.31
方案2	18.41	19.14	4.43	0.27
方案3	18.67	18.24	4.43	0.29
方案4	18.71	18.13	4.41	0.37
方案5	18.81	18.05	4.16	0.3
方案6	18.87	17.55	3.93	0.38

	m / kg	F_max / kN	d_max / mm	ε_pmax	有效性
基础	19.14	21.80	4.98	0.32	/
方案1	18.37	18.89	4.32	0.28	有效
方案2	18.41	20.14	5.03	0.29	无效
方案3	18.67	18.74	4.01	0.33	有效
方案4	18.71	18.32	4.2	0.3	有效
方案5	18.81	18.55	5.07	0.35	无效
方案6	18.87	17.53	3.63	0.39	有效