Integrated Design Technology for New Energy Vehicle Power Battery Systems

doi:10.3969/j.issn.1004-132X.2025.07.024

Abstract

Abstract: An integrated design technology of power battery systems for new energy vehicles was elaborated, and the advantages in space utilisation, range, and cost control were shown by analysing the technology such as moduleless, battery chassis integration and battery body integration. Other typical battery technology which promoted the development of automotive industry through structural innovation, thermal management optimisation and fast charging solutions were explored. The development directions of power battery system integration technology were outlooked in terms of intelligent integration, sustainable materials, and standardisation.

Key words: integration of power battery system, new energy vehicle, safety, lightweight

摘要： 阐述了新能源汽车动力电池系统的集成化设计技术，通过分析无模组、电池底盘一体化和电池车身一体化等技术展现了它们在空间利用、续航里程、成本控制等方面的优势。其他典型电池技术通过结构创新、热管理优化和快充方案推动了汽车产业的发展。从智能集成、可持续性材料和标准化三个方面展望了动力电池系统集成化技术的发展方向。

关键词: 动力电池系统集成化, 新能源汽车, 安全性, 轻量化

CLC Number:

U469.722

SHI Peicheng1, SHAN Zixian1, ZHU Hailong1, HAI Bin2, WANG Lei2, LU Fayan2. Integrated Design Technology for New Energy Vehicle Power Battery Systems[J]. China Mechanical Engineering, 2025, 36(07): 1611-1623.

时培成1, 单子贤1, 朱海龙1, 海滨2, 王磊2, 陆发燕2. 新能源汽车动力电池系统的集成化设计技术[J]. 中国机械工程, 2025, 36(07): 1611-1623.

References

［1］TAUB A,de MOOR E, LUO Alan, et al. Materials for Automotive Lightweighting［J］. Annual Review of Materials Research, 2019, 49:327-359.
［2］ROSENTHAL S, MAA F, KAMALIEV M, et al. Lightweight in Automotive Components by Forming Technology［J］. Automotive Innovation, 2020, 3(3):195-209.
［3］CECCHEL S．Materials and Technologies for Lightweighting of Structural Parts for Automotive Applications［J］．SAE International Journal of Materials and Manufacturing，2021，14(1)：81-98．
［4］SUN Y K. Promising All-solid-state Batteries for Future Electric Vehicles［J］. ACS Energy Letters, 2020, 5(10):3221-3223.
［5］WU Yingqiang, XIE Leqiong, MING Hai, et al. An Empirical Model for the Design of Batteries with High Energy Density［J］. ACS Energy Letters, 2020, 5(3):807-816.
［6］PROPFE B, REDELBACH M, SANTINI D, et al. Cost Analysis of Plug-in Hybrid Electric Vehicles Including Maintenance & Repair Costs and Resale Values［J］. World Electric Vehicle Journal, 2012, 5(4):886-895.
［7］JIN Changyong, SUN Yuedong, YAO Jian, et al. No Thermal Runaway Propagation Optimization Design of Battery Arrangement for Cell-to-chassis Technology［J］. eTransportation, 2022, 14:100199.
［8］比亚迪:搭载CTB技术的e平台3.0车型海豹开启预售，预售价格21.28万元起［J］. 中国质量万里行, 2022(6):39.
［9］JIANG Yahong, WU Qunqi, LI Min, et al. What Is Affecting the Popularity of New Energy Vehicles? A Systematic Review Based on the Public Perspective［J］.Sustainability, 2023, 15(18):13471.
［10］DENG Jie, BAE C, DENLINGER A, et al. Electric Vehicles Batteries:Requirements and Challenges［J］. Joule, 2020, 4(3):511-515.
［11］SHARMA S, PANWAR A K, TRIPATHI M M. Storage Technologies for Electric Vehicles［J］. Journal of Traffic and Transportation Engineering (English Edition), 2020, 7(3):340-361.
［12］ARORA S, SHEN Weixiang, KAPOOR A. Review of Mechanical Design and Strategic Placement Technique of a Robust Battery Pack for Electric Vehicles［J］. Renewable and Sustainable Energy Reviews, 2016, 60:1319-1331.
［13］ZHANG Ji, WANG Jianchang, LYU Xiangjie. Simulation Study on the Influence of the Shielding Mechanism of the Battery Pack Shell on the Vehicle Radiation Emission［EB/OL］. SAE Technical Paper, 2021［2024-05-10］. https:∥doi.org/10.4271/2021-01-0149.
［14］DOERR J, ARDEY N, MENDL G, et al. The New Full Electric Drivetrain of the Audi E-tron［M］∥Der Antrieb von Morgen 2019. Wiesbaden:Springer Fachmedien Wiesbaden, 2019:13-37.
［15］NICOLETTI L, ROMANO A, KNIG A, et al. An Estimation of the Lightweight Potential of Battery Electric Vehicles［J］. Energies, 2021, 14(15):4655.
［16］WASSILIADIS N, STEINSTRTER M, SCHREIBER M, et al. Quantifying the State of the Art of Electric Powertrains in Battery Electric Vehicles:Range, Efficiency, and Lifetime from Component to System Level of the Volkswagen ID.3［J］. eTransportation, 2022, 12:100167.
［17］XU Bin, ARJMANDZADEH Z. Parametric Study on Thermal Management System for the Range of Full (Tesla Model S)/ Compact-size (Tesla Model 3) Electric Vehicles［J］. Energy Conversion and Management, 2023, 278:116753.
［18］LIU Jinming, ANWAR M, CHIANG P, et al. Design of the Chevrolet Bolt EV Propulsion System［J］. SAE International Journal of Alternative Powertrains, 2016，5(1):79-86.
［19］LOISELLE-LAPOINTE A, CONDE A J, RIBBERINK H. Chevrolet Volt On-road Test Programs in Canada Part 1:Effects of Drive Cycle, Ambient Temperature and Accessory Usage on Energy Consumption and All-electric Range［J］. International Journal of Automotive Technology, 2017, 18(1):103-115.
［20］PHAM X M, BUI G V, PHAM H, et al. Design Process of Electric Vehicle Power System［J］. Applied Mechanics and Materials, 2022, 907:101-114.
［21］TROVO J P. Exploring Current Automotive Industry Trends［Automotive Electronics［J］. IEEE Vehicular Technology Magazine, 2023, 18(4):127-137.
［22］PISTOIA G, LIAW B. Behaviour of Lithium-ion Batteries in Electric Vehicles［M］. Cham:Springer International Publishing, 2018.
［23］ECKSTEIN L, SCHMITT F, HARTMANN B. Leichtbau Bei Elektrofahrzeugen［J］. ATZ—Automobiltechnische Zeitschrift, 2010, 112(11):788-795.
［24］SANGUESA J A, TORRES-SANZ V, GARRIDO P, et al. A Review on Electric Vehicles:Technologies and Challenges［J］. Smart Cities, 2021, 4(1):372-404.
［25］DONG Qingyin, LIANG Shuang, LI Jinhui, et al. Cost, Energy, and Carbon Footprint Benefits of Second-life Electric Vehicle Battery Use［J］. iScience, 2023, 26(7):107195.
［26］邱伟. 新能源汽车动力电池结构及成组技术综述［J］. 时代汽车, 2024(5):107-111.
QIU Wei. A Review of the Structure and Grouping Technology of Power Batteries for New Energy Vehicles［J］. Auto Time, 2024(5):107-111.
［27］金奎, 何鹏申. 新能源汽车电池车身一体化技术及工艺［J］. 汽车制造业, 2023(4):6-8.
［28］刘渺然, 翟旭亮, 吕宁, 等. 动力电池集成关键技术研究现状及展望［J］. 汽车文摘, 2023(4):1-6.
LIU Miaoran, ZHAI Xuliang, LYU Ning, et al. Research Status and Prospects on Key Technologies for Power Battery Integration［J］. Automotive Digest, 2023(4):1-6.
［29］朱龄. 新一代比亚迪唐的“一大步” 能否成为新能源汽车向前的“一小步”?［J］. 汽车纵横, 2018(7):68-69.
ZHU Ling. A New Generation of BYD Don’s “a Big Step” Can It Be a “Small Step” for New Energy Vehicles to Move Forward?［J］. AutoReview, 2018(7):68-69.
［30］YE Ben, RUBEL M R H, LI Hongjun. Design and Optimization of Cooling Plate for Battery Module of an Electric Vehicle［J］. Applied Sciences, 2019, 9(4):754.
［31］赫炎. 从CTP、CTC、CTB浅谈电动汽车动力电池集成技术［J］. 世界汽车, 2022(6):70-71.
［32］合创汽车打造全新CTP电池包让出行不再焦虑|续航|CTP［EB/OL］. (2022-03-20)［2025-03-16］. https:∥www.163.com/dy/article/H2U3MLAG05475 FX9.html.
［33］LI Jun, DAMIR KUDRYAKOV F. Ningde Times Company to Enter the International Market Form［C］∥The 2021 7th International Conference on Industrial and Business Engineering. Macau, 2021:253-258.
［34］特斯拉Model 3 三电系统拆解［EB/OL］. (2022-08-11)［2025-03-16］. http:∥www.360doc.com/content/22/0811/11/80174008_1043368363.shtml.
［35］朱小燕. 无模组技术在新能源汽车动力电池中的应用与研究［J］. 科技与创新, 2020(15):159-161.
ZHU Xiaoyan．Application and Research of Moduleless Technology in New Energy Vehicle Power Battery［J］．Technology and Innovation，2020(15)：159-161．
［36］陈南, 李兵兵. 电动汽车动力电池包结构设计分析研究进展［J］. 机械制造与自动化, 2022, 51(1):1-6.
CHEN Nan, LI Bingbing. Progress in Research and Analysis of Structural Design of Electric Vehicle Power Battery Pack［J］. Machine Building & Automation, 2022, 51(1):1-6.
［37］车家号, 发现车生活, 汽车之家. 刀片电池撑场，备受瞩目的比亚迪汉，能否成为老牌造车势力的反击［EB/OL］. (2023-06-01)［2025-03-16］. https:∥chejiahao.autohome.com.cn/info/5845869/.
［38］ZHANG Wen, XU Jun. Advanced Lightweight Materials for Automobiles:a Review［J］. Materials & Design, 2022, 221:110994.
［39］魏一凡, 韩雪冰, 卢兰光, 等. 面向碳中和的新能源汽车与车网互动技术展望［J］. 汽车工程, 2022, 44(4):449-464.
Wei Yifan, Han Xuebing, Lu Languang, et al. Carbon-neutral New Energy Vehicles and Vehicle-network Interaction Technologies［J］. Automotive Engineering, 2022, 44(4):449-464.
［40］李婷．宁德时代智能滑板底盘预计明年量产续航里程突破1000公里［N］．证券日报，2023-12-01(B01)．
［41］朱成明. 滑板底盘概述以及发展趋势［J］. 时代汽车, 2024(4):131-134.
ZHU Chengming. An Overview of Skateboard Chassis and Development Trends［J］. Auto Time, 2024(4):131-134.
［42］森宁. 美国专业团队拆解特斯拉Model Y的4680电池包，秘密全部揭晓！［EB/OL］. (2022-08-29)［2025-03-16］. https:∥hxny.com/nd-76486-0-50.html.
［43］挑战双面侧柱碰试验!比亚迪CTB技术成功通过［EB/OL］. (2023-07-26)［2024-04-09］. https:∥www.163.com/dy/article/IAJDL34H054777M8.html．
［44］薛海波, 程晓燕, 徐洋. 我国固态电池产业化发展的问题与进路［J］. 西南石油大学学报(社会科学版), 2024, 26(2):1-7.
XUE Haibo, CHENG Xiaoyan, XU Yang. Problems in the Industrialization of Solid-state Battery in China and Solutions［J］. Journal of Southwest Petroleum University (Social Sciences Edition), 2024, 26(2):1-7.
［45］揭秘上汽“魔方电池”［EB/OL］． (2022-08-11)［2024-04-18］. http:∥www.evobserver.com/archives/6910.
［46］燃擎技术课：销量不断突破的埃安，安全持续进化的弹匣电池［EB/OL］. (2023-07-10)［2025-03-16］. https:∥www.sohu.com/a/696310058_117438.
［47］岚图FREE 318［EB/OL］.［2025-03-16］. https:∥www.voyah.com.cn/free.html.
［48］富兰克林. 永不起火，永不爆炸” 深度解析长城大禹电池技术［EB/OL］. (2023-05-20)［2025-03-16］. https:∥www.xchuxing.com/article/38293.
［49］蒋立琴, 王记磊, 邹兴华, 等. GB 38031—2020《电动汽车用动力蓄电池安全要求》解析［J］. 电池, 2020, 50(3):276-279.
JIANG Liqin, WANG Jilei, ZOU Xinghua, et al. Analysis of GB 38031—2020 Safety Requirements of Traction Battery Used by Electric Road Vehicles［J］. Battery Bimonthly, 2020, 50(3):276-279.
［50］蔚来. 蔚来ET7智能电动行政轿车-NIO蔚来官网［EB/OL］.［2025-03-16］. https:∥www.nio.cn/et71.
［51］赖达聪, 王雨. 专为人民创造财富研发五菱红1号电池解析［EB/OL］. (2024-02-04)［2025-03-16］. https:∥www.12365auto.com/parts/20240204/521831.shtml.
［52］新能源情报分析网评测组. 从美国通用奥特能平台军用化，研判动力电池系统主被动安全（下）［EB/OL］. (2024-02-27)［2025-03-16］. https:∥www.sohu.com/a/752182121_117833.
［53］治愈“电动爹”三大痛点，详解极氪金砖电池［EB/OL］. (2023-12-25)［2025-03-16］. https:∥www.163.com/dy/article/IMQJOPDT0527E3LS.html.

[1]	ZHAO Cangpeng, DAI Liangcheng, CHI Maoru, GUO Zhaotuan, ZENG Pengcheng, SUN Baokai. Research on Applicability of Multi-functional Inter-vehicle External Vestibule Diaphragm in High-speed EMUs [J]. China Mechanical Engineering, 2025, 36(05): 1111-1122.
[2]	LI Peng1, 2, 3, 4, LI Mengcong1, 4, XIAO Libo2, 3, WANG Yitang1, 4, SONG Xueguan1, 4, YANG Ling5. Lightweight Design of Concrete Pump Truck Boom Pins Based on Multi-fidelity Surrogate Model [J]. China Mechanical Engineering, 2025, 36(04): 821-829.
[3]	XIN Jiaming1, JI Xiaogang1, 2, SUN Rong1, SU Yilin1. Study on Bending Performance of Bionic High-strength and Lightweight Pipe Structures [J]. China Mechanical Engineering, 2025, 36(02): 333-341.
[4]	WANG Dongwei, LI Faqiang, ZHAO Yang, HUANG Qichang, WANG Fanyu, LIU Bin. Tribological Performance of Electrical Contacts at Risk Frequency of Nuclear Safety Level DCS Equipment [J]. China Mechanical Engineering, 2024, 35(11): 2063-2070.
[5]	SU Yonglei, ZHANG Zhifei. Integrated Casting Triangular Beam Lightweight Improving with Multi-performance Constraints of Body Systems [J]. China Mechanical Engineering, 2024, 35(04): 691-699.
[6]	ZHANG Zhen, GUO Ce, HU Caiji, ZHENG Wei. Research on Self-repairing Structure Design and Repair Performance Based on Additive Manufacturing Technology [J]. China Mechanical Engineering, 2024, 35(01): 144-151.
[7]	SUN Haitao, ZHAN Mei, FAN Xiaoguang, GUO Jing, HAN Chao, ZHANG Jun. Research Progresses and Prospects of Compression Molding of High-performance PBX [J]. China Mechanical Engineering, 2024, 35(01): 160-180.
[8]	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.
[9]	ZHOU Guoqiang, WANG Hui, SONG Yuning, ZHAO Guochao, . Design of Double-stage Safety Valves for Hydraulic Support and Experimental Study of Their Rapid Dynamic Load Impact Test [J]. China Mechanical Engineering, 2023, 34(18): 2194-2203.
[10]	LI Guolong, ZHU Guohua, JIANG Lin, TAO Yijie, JIA Yachao. Optimization of Multi-objective Grinding Process Parameters to Suppress Chatter Marks [J]. China Mechanical Engineering, 2023, 34(09): 1086-1092.
[11]	CAO Teng, LI Xiaoniu, WANG Boquan, WEN Zhiyi, WU Dawei. Design of High Precision Apertures Driven by a Single Phase Piezoelectric Motor [J]. China Mechanical Engineering, 2022, 33(20): 2414-2419.
[12]	WANG Dengfeng, LI Shenhua. Lightweight Optimization Design of Side Collision Safety Parts for BIW Based on Pareto Mining#br# [J]. China Mechanical Engineering, 2021, 32(13): 1584-1590,1637.
[13]	LIU Yanyu;YU Fan;SONG Juanjuan;PANG Jisu;KAKU Chuyo. Detection of Brake Requests Using Neural Network and Fuzzy Control [J]. China Mechanical Engineering, 2020, 31(23): 2847-2855.
[14]	HUA Lin, WEI Pengfei, HU Zhili, . Green and Intelligent Forming Technology and Its Applications for High Strength Lightweight Materials [J]. China Mechanical Engineering, 2020, 31(22): 2753-2762,2771.
[15]	ZHANG Kaicheng；LI Shunming；SUN Mingjie. Lightweight Optimization Design of Commercial Vehicle Frames Combined by Steel and Aluminum Materials under Multiple Working Conditions [J]. China Mechanical Engineering, 2020, 31(18): 2206-2211，2219.