Optimization Design of Battery Box of Electric Vehicles Based on Response Surface Model

doi:10.12141/j.issn.1000-565X.230737

Abstract

Abstract:

In order to improve the performance of the battery box of electric vehicles and strengthen the safety and reliability of each component, the acceleration response of the battery modules at different positions inside the box was investigated with the battery box body of an electric vehicle, finding that the calculation results of the power spectral density curves of the three groups of battery modules in the z direction are in good agreement with the test results. Then, by considering the dimensional parameters, such as the top cover of the box, the front end parts of the box, the rear end parts of the box, the middle parts of the box, the module fixing brackets and the reinforcement parts, a response surface proxy model, which describes the relationship between the dimensional parameters of the battery box’s main parts and the intrinsic frequency, deformation as well as vibration response, was established, and the random vibration and the mechanical shock of the box were calculated, with the results verifying the correctness of the model. Based on the Box-Behnken response surface method for designing tests, several combinations of tests with six design variables and three levels were obtained, and the corresponding test design matrices were obtained. A polynomial response surface approximation model was fitted using multiple regression analysis, and the model was iterated and optimized using a multi-objective genetic algorithm to obtain the optimal dimensional parameters of the battery box. Experimental results show that, as compared with the original model, the first-order intrinsic frequency in the optimized case increases by 29.12%, the deformation reduces by 29.39%, and the vibration response reduces by 40.31%, which means a successful lightweighting. The modelling and analyzing methods in this paper can be used to calculate the influence of the battery box components on the overall structure of the battery box, improve the performance of the battery box through optimized design, and strengthen the safety and reliability of each component.

Key words: battery box, response surface model, random vibration, optimization design

CLC Number:

U461.91

WANG Ningzhen, QIN Kangjie, TANG Liang, SHANGGUAN Lijian, ZHOU Fupeng, SHANGGUAN Wenbin. Optimization Design of Battery Box of Electric Vehicles Based on Response Surface Model[J]. Journal of South China University of Technology(Natural Science Edition), 2024, 52(12): 43-51.

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序号	部件名称	钢材类型	单元类型	单元厚度/mm	单元边长/mm
1	箱体前端件	CR270BH	壳单元	1.5	5
2	箱体后端件	CR270BH	壳单元	1.5	5
3	箱体中部件	CR460LA	壳单元	1.5	5
4	箱体上盖	CR380LA	壳单元	1.0	5
5	模组固定支架	CR460LA	壳单元	1.5	3
6	加强件	CR460LA	壳单元	3.0	3
7	极柱支撑支架	CR460LA	壳单元	1.5	3
8	吊耳	CR460LA	壳单元	2.0	3

传感器编号	振动前共振频率/Hz	振动后共振频率/Hz	频率差/Hz
B1	90.2	83.7	6.5
B2	81.8 92.3 233.2	74.4 85.4 236.1	7.4
			6.9
			2.9
B3	91.7	88.2	3.5

变量符号	变量名称	取值范围/mm
a	箱体前端件厚度	1~4
b	箱体后端件厚度	1~4
c	箱体中部件厚度	1~4
d	箱体上盖厚度	1~3
e	模组固定支架厚度	1~2
f	加强件厚度	1~4

编号	电池箱体结构参数						输出结果
编号	a	b	c	d	e	f	最小固有频率/Hz	变形量/mm	最大应力均方根/MPa
1	2.5	1.0	2.5	2.0	1.0	2.0	28.98	11.53	131.0
2	3.0	2.5	2.5	1.0	1.0	3.5	29.80	18.44	152.8
3	2.5	2.5	2.5	2.0	1.5	3.5	29.76	11.00	104.5
4	2.5	2.5	2.5	2.0	1.5	3.5	29.76	11.00	104.5
︙	︙	︙	︙	︙	︙	︙	︙	︙	︙
53	3.5	3.5	3.5	2.0	1.5	3.0	33.54	9.04	56.6
54	2.5	4.0	4.0	2.0	1.0	3.5	29.76	11.00	104.5

设计变量（输入）	不同方案的变量取值
设计变量（输入）	方案1	方案2	方案3
a/mm	2.23	3.35	1.56
b/mm	2.40	3.26	3.58
c/mm	3.31	1.13	2.95
d/mm	2.60	1.32	1.87
e/mm	1.59	1.80	1.68
f/mm	3.81	2.49	3.09