基于VRB/OW-GFRP混合结构的CTB电池包上盖总成轻量化设计研究

doi:10.19562/j.chinasae.qcgc.2024.02.011

Abstract

Abstract:

Cell to body （CTB） is a key technology to improve the endurance mileage of electric vehicles. The VRB/OW-GFRP hybrid structure formed by the variable-thickness rolled blanks （VRB） structure and the orthotropic woven GFRP （OW-GFRP） through the bonding process is an innovative structure， which can reduce the weight of the CTB battery pack， thus improve the endurance mileage of electric vehicles. Taking an electric vehicle as the research object， a CTB battery body integrated structure is designed to realize the integration of the upper cover of the battery pack and the floor of car body. Furthermore， the cover assembly of the uniform thickness （UT） CTB battery pack are replaced by the VRB structure， UT/OW-GFRP and VRB/OW-GFRP hybrid structure. The lightweight design of the upper cover assembly of the three types of CTB battery pack are carried out based on the multi-stage optimization method. The results show that the weight of VRB structure is reduced by 6.4% compared with that of UT structure when the stiffness performance of the CTB battery pack is met. The lightweight level of the upper cover assembly of the CTB battery pack based on the VRB/OW-GFRP hybrid structure is about three times that of the metal structure， with the weight of the VRB/OW-GFRP reduced further by 4.2% compared with that of the UT/OW-GFRP hybrid battery pack upper cover assembly. Thus， the VRB/OW-GFRP hybrid structure is the inevitable trend of the development of automotive lightweight technology in the future， showing a great application prospect in CTB battery pack cover assembly.

Key words: VRB/OW-GFRP, hybrid structure, CTB, battery pack, lightweight

Libin Duan,Yu Zhang,Zhanpeng Du,Yegang Liu,Xiangxin Meng,Guannan Tian,Haiyang Zheng,Chuang Wu. Research on Lightweight Design of CTB Battery Pack Cover Assembly Based on VRB/OW-GFRP Hybrid Structure[J].Automotive Engineering, 2024, 46(2): 290-299.

Figures/Tables 29

References 11

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部件名称	材料	密度/ （g·cm^-3）	弹性模量E/ GPa	泊松比
座椅横梁、边框等	高强钢	7.85	210	0.3
液冷板	铝合金	2.7	70	0.3
灌封胶	环氧树脂	1.2	2.3	0.4
电芯	镍钴锰	2.7	63	0.33

零件	变量类型	符号	下限/mm	上限/mm	初始值/mm
VRB上盖	厚度变量	t₁~t₃₇	0.9	1.8	1.2
VRB座椅横梁	厚度变量	t₃₈~t₆₅	0.9	1.8	1.4

零件	组分	变量类型	符号	下限/mm	上限/mm	初始值/mm
UT/OW-GFRP 混合上盖	UT	厚度变量	t₆₆	0.9	1.8	1.2
	OW-GFRP	厚度变量	t₆₇~t₇₁	0.05	0.2	0.15
	OW-GFRP	顺序变量	s₁~s₅
UT/OW-GFRP 混合座椅横梁	UT	厚度变量	t₇₂	0.9	1.8	1.2
	OW-GFRP	厚度变量	t₇₃~t₇₇	0.05	0.2	0.15
	OW-GFRP	顺序变量	s₆~s₁₀

零件	组分	变量类型	符号	下限/mm	上限/mm	初始值/mm
VRB/OW-GFRP 混合上盖	VRB	厚度变量	t₁~t₃₇	0.9	1.8	1.2
	OW-GFRP	厚度变量	t₆₇~t₇₁	0.05	0.2	0.15
	OW-GFRP	顺序变量	s₁~s₅
VRB/OW-GFRP 混合座椅横梁	VRB	厚度变量	t₃₈~t₆₅	0.9	1.8	1.2
	OW-GFRP	厚度变量	t₇₃~t₇₇	0.05	0.2	0.15
	OW-GFRP	顺序变量	s₆~s₁₀

输出响应	初始值
质量M/kg	45.6
弯曲刚度K_b/（N·m^-1）	7 410
扭转刚度K_t/（N·m·（°）^-1）	6 560

Research on Lightweight Design of CTB Battery Pack Cover Assembly Based on VRB/OW-GFRP Hybrid Structure

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Figures/Tables 29

References 11

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优化问题	结构类型	初始质量/kg	优化后质量/kg	减质量比例/%	弯曲刚度/（N·mm^-1）	扭转刚度/ （N·mm·（°）^-1）
初始状态	UT结构	45.56			7 407	6 560
第1类优化问题	VRB结构	45.56	42.70	6.4	7 394	6 656
第2类优化问题	UT/OW-GFRP混合结构	55.52	38.74	15.0	7 449	6 661
第3类优化问题	VRB/OW-GFRP混合结构	55.52	37.08	18.7	7 440	6 647

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