CN116956492A - New energy light truck frame bearing type power battery bracket lightweight design method - Google Patents
New energy light truck frame bearing type power battery bracket lightweight design method Download PDFInfo
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- 238000013461 design Methods 0.000 title claims abstract description 80
- 238000000034 method Methods 0.000 title claims abstract description 51
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- 238000004458 analytical method Methods 0.000 claims abstract description 25
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- 238000012360 testing method Methods 0.000 claims description 9
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- 229910000838 Al alloy Inorganic materials 0.000 claims description 6
- 238000003466 welding Methods 0.000 claims description 6
- 229910052782 aluminium Inorganic materials 0.000 claims description 5
- 238000009826 distribution Methods 0.000 claims description 5
- 238000005452 bending Methods 0.000 claims description 4
- 238000004519 manufacturing process Methods 0.000 claims description 4
- 230000000452 restraining effect Effects 0.000 claims description 4
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- 229910000831 Steel Inorganic materials 0.000 claims description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 2
- 238000010438 heat treatment Methods 0.000 claims description 2
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Abstract
The invention discloses a new energy light-truck frame bearing type power battery bracket lightweight design method, which comprises the following steps: 1) According to the development target of the power battery bracket, acquiring boundary conditions of the power battery pack, and confirming development design requirements of the power battery bracket; 2) The forward design method of the power battery bracket structure is described from three light weight approaches including materials, structures and processes through standard analysis performance, weight and cost, and a light weight technical route of the power battery bracket is formulated; 3) The power battery support modularization, integration, light weight design and performance simulation analysis are completed, and performance analysis evaluation standards are formulated; 4) The method for designing the complete and mature frame-bearing power battery bracket forward light weight is formed. The invention realizes the light weight target of the product, reduces the development cost, shortens the development period and meets the requirement of continuous and rapid development of the new energy electric light card.
Description
Technical Field
The invention belongs to the technical field of battery frames, and particularly relates to a new energy light-truck frame bearing type power battery bracket lightweight design method.
Background
In the face of demands of urban distribution logistics transportation development and pain points of users, new energy light trucks change electricity from original oil to forward development of better chassis overall layout, higher energy density and lighter forward design, and the application of the integrated power battery pack reduces dead weight and energy consumption of the whole vehicle, so that the gravity center of the whole vehicle is more stable, the endurance is increased, and the integrated power battery pack is a necessary development trend in the future. The power battery support is a main structure for bearing the power battery, and the modularized, integrated and light-weight design of the structure is becoming the technical research and development direction of various large-scale vehicles and part enterprises.
At present, a method frequently adopted for the light-weight design of the new energy electric light-card power battery bracket is simple material replacement, and the structure and process which are complementary to the material and the systematic light-weight design flow which is balanced with the performance are omitted.
The prior patent document number is CN201920784264.9 light electric vehicle power battery mounting frame structure, which comprises two or more groups of power battery frame supporting assemblies, a lower power battery frame, an upper power battery frame and a connecting bracket; the upper power battery frame is fixed on the lower power battery frame through bolts. The upper power battery frame is of an open design, and the power battery positioned on the upper layer is exposed and is required to be redesigned and improved when being mounted on a light truck body.
The prior art patent document number CN202210706970.8 is a design method of a cross beam structure of a battery shell of an electric automobile, and discloses a method for analyzing the structure of the frame of the power battery shell of the electric automobile and determining the design condition of the frame of the battery shell; performing test working condition simulation by using a three-dimensional model design and a load check model to ensure that the battery shell frame structure meets the design conditions; determining a lightweight topological optimization boundary condition of the battery shell frame beam; developing the topological optimization structural design of the cross beam under multiple working conditions; and performing performance check on the battery shell frame aiming at the optimized beam light topological optimization structure. In the above battery frame design method, by performing test condition simulation on the whole battery frame, after the beam topology is optimized, the performance of the battery frame is checked again, and the design of how to expand the lightweight technical route of the battery frame is also required to be optimized from multiple dimensions.
Accordingly, there is a need for a design method for forward designing a power cell support structure from a variety of lightweight approaches.
Disclosure of Invention
The invention aims to solve the technical problems and provide a new energy light-truck frame bearing type power battery bracket light-weight design method, so that the product light-weight target is realized, the development cost is reduced, the development period is shortened, and the requirement of continuous and rapid development of new energy electric light trucks is met. In order to achieve the above purpose, the technical scheme of the invention is as follows:
the light design method of the new energy light card frame bearing type power battery bracket comprises the following steps:
1) According to the development target of the power battery bracket, acquiring boundary conditions of the power battery pack, and confirming development design requirements of the power battery bracket;
2) The forward design method of the power battery bracket structure is described from three light weight approaches including materials, structures and processes through standard analysis performance, weight and cost, and a light weight technical route of the power battery bracket is formulated;
3) The power battery support modularization, integration, light weight design and performance simulation analysis are completed, and performance analysis evaluation standards are formulated;
4) The method for designing the complete and mature frame-bearing power battery bracket forward light weight is formed.
Compared with the prior art, the novel energy light-truck frame bearing type power battery bracket lightweight design method has the following main beneficial effects:
according to the forward design requirement of the power battery bracket product, the lightweight technical route of the product is comprehensively spread from a new structure, a new material and a new process; the product performance is ensured through simulation and test check of typical working conditions, and meanwhile, the design of modularization, integration, serialization and light weight of the product is realized; the method can be applied to the light weight design of products in similar structural forms, realizes the light weight goal of the products, reduces the development cost, shortens the development period and meets the requirement of continuous and rapid development of new energy electric light cards.
Drawings
FIG. 1 is a flow chart of a design method according to an embodiment of the invention;
fig. 2 is a schematic view of a power battery bracket structure according to an embodiment.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely, but is apparent to those skilled in the art in view of the present invention.
Examples:
referring to fig. 1, the embodiment is a new energy light truck frame-carried power battery bracket lightweight design method, which includes the following steps:
1) According to the development target of the power battery bracket, acquiring boundary conditions of the power battery pack, and confirming development design requirements of the power battery bracket;
the development target of the power battery bracket is defined as developing a power battery bracket suitable for a new energy van-type electric light card, and the light weight is realized through materials, structures and processes under the condition of meeting the performance requirements of structural modes, rigidity, strength and fatigue of the power battery bracket; taking the maximum utilization of chassis space and the stability of the vehicle into consideration, the power battery pack adopts double-layer side-hanging arrangement, and a primary steel-aluminum mixed frame bearing type structural form is adopted;
the integrated power battery pack information is defined as 4X TX8, electricity quantity 162.28kWh and weight 1159kg, and each battery pack is fixed on a power battery support middle-layer support assembly and a power battery support lower-layer support assembly through 10M 12 bolts and is arranged in a double-layer side-hanging mode;
the arrangement requirement of the integrated power battery pack on the new energy electric van-type light truck chassis is that under the whole vehicle coordinate system (defining that an X axis points to the advancing direction of the vehicle, a Y axis points to the left side of the vehicle and a Z axis points to the vertical upper side of the vehicle), the X direction is arranged in the middle position of the front and rear leaf spring mounting seats of the chassis frame, and front and rear axle loads are checked; the Y direction is hung on the outer side of the frame girder through a power battery bracket; the Z direction is arranged below the floor of the independent cargo compartment, so that the clearance requirement of the upper part and the lower part of the full-load state is met;
development design requirements of the power battery support include: 1-1) considering the mode frequency of an assembly including a power battery pack, and avoiding the random excitation of a road surface and the common working frequency of a motor in the normal running state of a vehicle;
1-2) the bearing of the power battery pack is satisfied, and the bracket and the connecting structure thereof are required to bear impact loads under the working conditions of vertical jolt, forward braking, reverse braking, left turning, right turning and the like;
1-3) according to GB/T31467.3, vibration fatigue simulation or test of the power battery support is carried out, and after vibration test is carried out for 12 hours along each direction of X/Y/Z, the maximum damage value of the power battery support structure is smaller than 1.
2) The forward design method of the power battery bracket structure is illustrated from three light weight approaches (materials, structures and processes) through standard analysis performance/weight/cost, and a light weight technical route of the structure is formulated;
the original power battery bracket scheme is aimed at realizing weight reduction and cost reduction on the premise of meeting the performance requirement of a power battery pack assembly, and the development and design weight point is the application of a light weight technology;
making a lightweight technical route of the power battery bracket, comprising: 2-1) in terms of materials, aluminum alloy gradually becomes a main material for realizing the weight reduction of automobiles due to the advantages of small density, good processability, capability of obtaining different degrees of reinforcement through work hardening or heat treatment, good corrosion resistance and the like; 2-2) in terms of structure, the frame bearing type aluminum battery frame structure can meet the strength requirements of different structures, is easier to realize light weight, and meets the dynamic and static performance requirements through material distribution in a CAE simulation optimization structure; 2-3) in the aspect of process connection, the connection and the fastening of the power battery bracket and the frame are mainly considered, so that the requirements of bearing impact and fatigue are met, and the connection stability and the assembly convenience between different materials are met;
3) The power battery support modularization, integration, light weight design and performance simulation analysis are completed, and performance analysis evaluation standards are formulated;
the forward design dimension from material, structure and process is used for completing the modularization, integration and light-weight design of the power battery support, and the forward design dimension comprises the following steps:
3-1) multi-material mixing design of the power battery bracket, wherein the factors such as strength, rigidity, corrosion resistance and the like of materials are required to be considered so as to ensure the light weight effect and the stability of the bracket structure;
3-2) the rigid design of the power battery bracket, and the factors such as the structure, the materials, the connection mode and the like of the bracket are required to be considered so as to ensure the strength and the rigidity of the bracket structure, so that the bracket structure can bear various loads and impacts of a vehicle in the running process;
3-3) modular design of the power battery bracket, namely decomposing the bracket design into a plurality of modules, independently manufacturing each module, and assembling the modules into a complete bracket assembly, so that the flexibility and maintainability of the bracket assembly can be improved, and the manufacturing cost and period can be reduced;
3-4) integrated design of the power battery bracket, wherein the coordination and cooperation among all parts or modules are mainly considered so as to realize the high efficiency and stability of the bracket assembly and the balance of the performance and the cost effectiveness of the bracket assembly;
3-5) the lightweight design of the power battery bracket is to reduce the weight of the bracket as much as possible on the premise of ensuring the strength and the rigidity of the bracket, and the lightweight material and the advanced manufacturing technology are needed to complement each other; 3-6) defining a power battery support as a steel-aluminum hybrid frame bearing structure, designing a section of a power battery support beam assembly, and calculating a section moment of inertia; considering that the power battery pack is arranged in a single-side double-layer manner, the power battery bracket beam assembly is mainly used for resisting vertical impact, the power battery bracket column assembly is mainly used for resisting longitudinal torsion, and the power battery bracket is positioned in the middle of the light truck frame, so that the bending resistance and torsion resistance of the frame chassis assembly are further affected; defining a power battery support beam as a high-strength steel material, calculating the bending stiffness and the yield force of a section, and comparing an original support scheme to perform preliminary evaluation;
3-7) selecting high-performance high-strength and high-toughness aluminum alloy sections according to a light weight target, and taking the high-performance high-strength and high-toughness aluminum alloy sections as structural frameworks of a lower bracket assembly and an intermediate bracket assembly of the power battery bracket, so that expansion in the length and width directions is conveniently realized; selecting laser welding with large penetration and small heat affected zone with the same heat input quantity to realize the split of the self frame so as to ensure the minimum welding deformation and material performance loss; selecting cold connection of riveting and screwing, realizing dissimilar material connection and integrated connection of all modules so as to ensure high rigidity and stability of the whole bracket assembly; 3-8) completing the structural design of the power battery support, wherein the power battery support comprises a power battery support beam assembly, a power battery support column assembly, a power battery support middle layer support assembly, a power battery support lower layer support assembly and a power battery support upper shield assembly, as described with reference to fig. 2;
the power battery support beam assembly consists of a plurality of beam structures, and the power battery support column assembly is vertically arranged relative to the power battery support beam assembly and used for limiting and fixing the power battery support middle layer support assembly and the power battery support lower layer support assembly. The middle layer support assembly of the power battery support and the lower layer support assembly of the power battery support are overlapped and arranged on two sides of the beam assembly of the power battery support. The power battery support upper shield assembly is arranged at the top of the power battery support middle layer support assembly and used for shielding the power battery pack in the power battery support upper shield assembly and enhancing the connection and fixation effects.
Performing simulation performance analysis on the mode, strength and fatigue of the structure of the power battery bracket, and formulating an evaluation standard for the simulation performance of the power battery bracket;
3-9) establishing a finite element model of the whole frame and the frame of the power battery bracket, wherein the finite element model comprises the step of adopting a sheet unit to simulate a frame structure; adopting a rigid unit to simulate cold connection and welding; applying a power battery pack mass counterweight; performing constraint modal analysis, wherein the result frequency needs to avoid random excitation of a road surface and the common working frequency of a motor in a normal running state of a vehicle;
3-10) carrying out impact strength analysis working conditions of a finite element model of the power battery bracket, wherein the working conditions comprise restraining all degrees of freedom of the front end face and the rear end face of the frame; simulating a vertical impact bearing working condition by applying a gravity acceleration along a Z axis; simulating the impact working condition of forward braking and reverse braking by applying the gravity acceleration along the +/-X axis; simulating impact working conditions of left turning and right turning along the gravity acceleration of the + -Y axis; performing strength analysis, wherein the maximum stress of the result meets the requirement of the minimum safety coefficient under each working condition;
3-11) performing vibration fatigue simulation of the power battery bracket according to GB/T31467.3, wherein the vibration fatigue simulation comprises the step of restraining all degrees of freedom of mounting points of the battery bracket; obtaining stress distribution of the bracket under the impact of unit acceleration in three directions of X/Y/Z through modal frequency response analysis; and (3) applying a PSD curve according to the vibration test requirement, performing vibration fatigue analysis, and after 12 hours of vibration test in each direction, enabling the maximum damage value to be smaller than 1.
4) The method for forming a complete and mature frame-carried power battery bracket forward light-weight design comprises the following steps of 1) to 3)
4-1) starting from a product development target, firstly obtaining design boundary conditions and confirming development design requirements; 4-2) detailing the material, structure and technological properties of the marker post product;
4-3) refocusing the light weight target, and constructing a light weight technical route from advanced materials, advanced processes and structural scheme ideas;
4-4) carrying out multi-material mixed design, rigid design, modularized design and integrated design on the product, and finally realizing light-weight design;
4-5) building a finite element model of the product, analyzing and optimizing the mode, the strength and the fatigue of the product, and simultaneously building a design simulation method, an analysis standard and an evaluation system aiming at the product.
When the embodiment is applied, the lightweight technical route of the product is comprehensively spread from a new structure, a new material and a new process according to the forward design requirement of the power battery bracket product; the product performance is ensured through simulation and test check of typical working conditions, and meanwhile, the design of modularization, integration, serialization and light weight of the product is realized; the method can be applied to the light weight design of products in similar structural forms, realizes the light weight goal of the products, reduces the development cost, shortens the development period and meets the requirement of continuous and rapid development of new energy electric light cards.
In the description of the present specification, the term "particular embodiment" or "a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, schematic representations of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.
Although the embodiments of the present invention are described above, the embodiments are only used for facilitating understanding of the present invention, and are not intended to limit the present invention. Any person skilled in the art can make any modification and variation in form and detail without departing from the spirit and scope of the present disclosure, but the scope of the present disclosure is to be determined by the appended claims.
Claims (10)
1. The light-weight design method of the new energy light-weight card frame bearing type power battery bracket is characterized by comprising the following steps of:
1) According to the development target of the power battery bracket, acquiring boundary conditions of the power battery pack, and confirming development design requirements of the power battery bracket;
2) The forward design method of the power battery bracket structure is described from three light weight approaches including materials, structures and processes through standard analysis performance, weight and cost, and a light weight technical route of the power battery bracket is formulated;
3) The power battery support modularization, integration, light weight design and performance simulation analysis are completed, and performance analysis evaluation standards are formulated;
4) The method for designing the complete and mature frame-bearing power battery bracket forward light weight is formed.
2. The new energy light truck frame-carried power battery bracket lightweight design method according to claim 1, characterized in that: step 2) comprises
The original power battery bracket scheme is used for realizing weight reduction and cost reduction on the premise of meeting the performance requirement of the power battery pack assembly, and the development and design weight point is the application of the light weight technology.
3. The new energy light truck frame-carried power battery bracket lightweight design method according to claim 2, characterized in that: in the step 2), a lightweight technical route of the power battery bracket is established, wherein the lightweight technical route comprises material aspects, and aluminum alloy can be strengthened to different degrees through work hardening or heat treatment;
in terms of structure, the frame bearing type aluminum battery frame structure can meet the strength requirements of different structures, and the material distribution in the structure is optimized through CAE simulation, so that the dynamic and static performance requirements are met;
in the aspect of process connection, the connection fastening of the power battery bracket and the frame is considered, so that the requirements of bearing impact and fatigue are met, and the connection stability and the assembly convenience between different materials are met.
4. The new energy light truck frame-carried power battery bracket lightweight design method according to claim 1, characterized in that: step 3) specifically comprises the following steps,
3-1) the multi-material mixing design of the power battery bracket, the strength, the rigidity and the corrosion resistance of the materials are required to be considered so as to ensure the light weight effect and the stability of the bracket structure,
3-2) rigid design of the power battery support, the structure, the materials and the connection mode of the support are required to be considered to ensure the strength and the rigidity of the support structure so as to enable the support structure to bear various loads and impacts of a vehicle in the driving process, 3-3) modular design of the power battery support is to decompose the support design into a plurality of modules, each module is independently manufactured and then assembled into a complete support assembly, the flexibility and the maintainability of the support assembly are improved, the manufacturing cost and the period are reduced,
3-4) an integrated design of the power cell support, taking into account the coordinated cooperation between the components or modules to achieve the high efficiency and stability of the support assembly, and a balance of performance and cost effectiveness thereof,
3-5) the lightweight design of the power battery bracket reduces the weight of the bracket on the premise of ensuring the strength and the rigidity of the bracket.
5. The new energy light truck frame-carried power battery bracket lightweight design method according to claim 4, characterized in that: step 3) specifically comprises the following steps,
3-6) defining a power battery support as a steel-aluminum hybrid frame bearing structure, designing a section of a power battery support beam assembly, and calculating a section moment of inertia; considering that the power battery pack is arranged in a single-side double-layer manner, the power battery bracket beam assembly is mainly used for resisting vertical impact, the power battery bracket column assembly is mainly used for resisting longitudinal torsion, and the power battery bracket is positioned in the middle of the light truck frame, so that the bending resistance and torsion resistance of the frame chassis assembly are further affected; and defining the power battery support beam as a high-strength steel material, calculating the bending stiffness and the yield force of the section, and comparing with the original support scheme to perform preliminary evaluation.
6. The new energy light truck frame-carried power battery bracket lightweight design method according to claim 5, characterized in that: step 3) specifically comprises the following steps,
3-7) selecting high-performance high-strength and high-toughness aluminum alloy sections according to a light weight target, and taking the high-performance high-strength and high-toughness aluminum alloy sections as structural frameworks of a lower bracket assembly and an intermediate bracket assembly of the power battery bracket, so as to realize expansion in the length and width directions; selecting laser welding with large penetration and small heat affected zone with the same heat input quantity to realize the split of the self frame so as to ensure the minimum welding deformation and material performance loss; and the cold connection of riveting and screwing is selected, so that the connection of dissimilar materials and the integrated connection of all modules are realized, and the overall high rigidity and stability of the bracket assembly are ensured.
7. The new energy light truck frame-carried power battery bracket lightweight design method as defined in claim 6, wherein the method is characterized by comprising the following steps: step 3) specifically comprises the following steps,
3-8) completing the structural design of the power battery bracket, wherein the structural design comprises a power battery bracket beam assembly, a power battery bracket upright post assembly, a power battery bracket middle layer bracket assembly, a power battery bracket lower layer bracket assembly and a power battery bracket upper shield assembly;
the power battery support beam assembly consists of a plurality of beam structures, the power battery support column assembly is vertically installed relative to the power battery support beam assembly, the power battery support middle layer support assembly and the power battery support lower layer support assembly are overlapped and arranged on two sides of the power battery support beam assembly, and the power battery support upper shield assembly is installed at the top of the power battery support middle layer support assembly.
8. The new energy light truck frame-carried power battery bracket lightweight design method as defined in claim 7, wherein the method is characterized by comprising the following steps: step 3) specifically comprises the following steps,
performing simulation performance analysis on the mode, strength and fatigue of the structure of the power battery bracket, and formulating an evaluation standard for the simulation performance of the power battery bracket;
3-9) establishing a finite element model of the whole frame and the frame of the power battery bracket, wherein the finite element model comprises the step of adopting a sheet unit to simulate a frame structure; adopting a rigid unit to simulate cold connection and welding; applying a power battery pack mass counterweight; and (3) carrying out constraint modal analysis, wherein the result frequency needs to avoid random excitation of the road surface and the common working frequency of the motor in the normal running state of the vehicle.
9. The new energy light truck frame-carried power battery bracket lightweight design method of claim 8, characterized by: step 3) specifically comprises the following steps,
3-10) carrying out impact strength analysis working conditions of a finite element model of the power battery bracket, wherein the working conditions comprise restraining all degrees of freedom of the front end face and the rear end face of the frame; simulating a vertical impact bearing working condition by applying a gravity acceleration along a Z axis; simulating the impact working condition of forward braking and reverse braking by applying the gravity acceleration along the +/-X axis; simulating impact working conditions of left turning and right turning along the gravity acceleration of the + -Y axis; and (3) carrying out strength analysis, wherein the maximum stress of the result meets the requirement of the minimum safety coefficient under each working condition.
10. The new energy light truck frame-carried power battery bracket lightweight design method according to claim 9, characterized in that: step 3) specifically comprises the following steps,
3-11) performing vibration fatigue simulation of the power battery bracket, including restraining all degrees of freedom of the mounting points of the battery bracket; obtaining stress distribution of the bracket under the impact of unit acceleration in three directions of X/Y/Z through modal frequency response analysis; and (5) applying a PSD curve according to the vibration test requirement, and performing vibration fatigue analysis.
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| CN118211330A (en) * | 2024-05-16 | 2024-06-18 | 山东轴研精密轴承有限公司 | Chassis hub bearing unit lightweight system of heavy-duty commercial vehicle |
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