重型新能源商用车换电箱轻量化设计

朱秀文¹，李伟¹，张东江²，周帅^1*，王彤¹

1.山东交通学院汽车工程学院，山东 济南  250357；2.上海玖行能源科技有限公司，上海  201821

摘要：为解决换电式重卡换电箱质量过大的问题，在保证可靠性和安全性的前提下，对某重型纯电动商用车换电箱框架进行轻量化设计，采用有限元分析轻量化换电箱的约束模态、静强度、变形，结合台架振动试验与整车强化坏路试验进行验证。结果表明：轻量化设计后，换电箱质量由735 kg减轻至426 kg；换电箱优化后的一阶振型模态频率为12.24 Hz，满足模态频率大于10.00 Hz的要求；前进中紧急制动、右急转弯、向上颠簸工况、换电提升4种典型工况的安全因数为2.18~3.19，均超过1.25，静强度满足设计要求；4种工况下换电箱最大变形为5.90 mm，满足企业技术标准要求。台架试验及坏路试验结果表明换电箱外观完好无损，未见任何损坏迹象，满足使用要求。

关键词：轻量化；换电箱；载荷谱采集；有限元分析；整车试验

Lightweight design of the battery swap box for a heavy-duty new energy commercial vehicle

ZHU Xiuwen¹, LI Wei¹, ZHANG Dongjiang², ZHOU Shuai^1*, WANG Tong¹

1.School of Automotive Engineering, Shandong Jiaotong University, Jinan 250357, China；

2.Shanghai Enneagon Energy Technology Co., Ltd., Shanghai 201821, China

Abstract: In order to solve the problem of excessive mass of the battery swap box for heavy-duty trucks, the framework of the battery swap box for a certain heavy-duty pure electric commercial vehicle is lightweight under the premise of ensuring reliability and safety. The constraint mode, static strength and deformation of the lightweight battery swap box are analyzed by finite element method, and verified by vibration test and full vehicle reinforcement bad road test. The analysis results show that after lightweight design, the mass of the battery swap box is reduced from 735 kg to 426 kg，the first order modal frequency of the improved battery swap box is 12.24 Hz, which meets the requirement of modal frequency greater than 10.00 Hz, the safety factor of the four typical working conditions of emergency braking, right emergency turning, upward jolting and battery swapping lifting are 2.18~3.19，all exceed 1.25, and the static strength meets the design requirements. The maximum deformation of the battery swap box under the four working conditions is 5.90 mm, which meets the requirement of enterprise technical standards. The results of the bench test and the bad road test show that appearance of the battery swap box is intact without any signs of damage, meeting the requirements for use.

Keywords: lightweight; battery swap box; load spectrum collection; finite element analysis; vehicle testing