Lightweight Design of Protective Structures of Battery Packs for Bottom-scraping Safety

doi:10.3969/j.issn.1004-132X.2023.19.009

Abstract

Abstract: To protect the battery pack from bottom-scraping， a section-layout design method for aluminium alloy protective structures was proposed. Firstly， a simulation model of the bottom-scraping of the vehicle was established and the intrusion target of the battery pack module was defined. The accuracy of the material was verified by three-point static pressure tests and simulation analysis on the anticollision beam. Secondly， the “人” glyph optimal cross-section was determined through topology optimization. Then the effects of different section shapes， installation positions and layout parameters on the bottom-scraping performance were compared and analyzed. The mechanism of bottom-scraping protection was investigated. Finally， hybrid approximation models were constructed and the MOMPA was used to optimize the section-layout of the structures. The results show that the two optimized aluminium alloy protection structures are 59.6% and 46.8% lighter than the original steel structures， respectively， and the battery module intrusions meet the requirements.

Key words: battery pack bottom-scraping, aluminum alloy, topology optimization, multi-objective marine predator algorithm（MOMPA）, lightweight

摘要： 为保护刮底工况中的电池包，提出了一种铝合金防护结构的截面-布置设计方法。建立了整车刮底仿真模型，并定义了电池包模组侵入量目标，通过对防撞梁进行三点静压试验和仿真分析验证了材料模型的准确性；对铝合金防护梁的截面进行拓扑优化，确定了防护结构的最优截面形状为“人”字形结构；对比分析了不同截面形状、安装位置和布置参数对刮底性能的影响，并研究了刮底防护的机理；最后，构建了混合近似模型，采用多目标海洋捕食者算法对结构进行截面-布置优化。研究结果表明，优化后的两种铝合金防护结构方案与原钢制结构方案相比，分别减重59.6%和46.8%，且电池模组侵入量满足要求。

关键词: 电池包刮底, 铝合金, 拓扑优化, 多目标海洋捕食者算法, 轻量化

CLC Number:

U463.83

WANG Chao, CHENG Aiguo, ZHANG Chenglin, YU Wanyuan, HE Zhicheng. Lightweight Design of Protective Structures of Battery Packs for Bottom-scraping Safety[J]. China Mechanical Engineering, 2023, 34(19): 2343-2352.

王超, 成艾国, 张承霖, 于万元, 何智成. 面向刮底安全的电池包防护结构轻量化设计[J]. 中国机械工程, 2023, 34(19): 2343-2352.

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