Design of Battery Pack Enclosure Structure for Electric Conversion Vehicle

Electric conversion vehicles are an alternative transportation solution, effectively reducing greenhouse gas emissions. The battery, serving as the primary energy storage component, is safeguarded within a battery pack enclosure to protect it from potentially contaminated road debris. The efficient design of battery pack enclosures is a crucial concern for ensuring the safety of electric vehicles. Therefore, this study aims to utilize topography, topology and size optimization techniques to enhance the design of the battery pack enclosure by considering normal operating conditions, natural frequency, and impact loading from road debris contamination. A finite element model is implemented to analyze structural strength under the desired loading conditions using HyperWorks. A preliminary analysis of the battery pack enclosure indicated that the impact loading scenario is the most severe condition and requires particular attention in the design process. Topography optimization techniques were employed to design the beading of the outer component. The layout of the internal member was determined through topology optimization, aiming to minimize structural displacement. The results demonstrated that the optimized battery pack enclosure successfully met all structural requirements and achieved a 73.2% reduction in displacement compared to the baseline model despite a slight increase in structural weight.