Optimization and Structural Analysis of Automotive Battery Packs Using ANSYS

The development of new energy vehicles, particularly electric vehicles, is robust, with the power battery pack being a core component of the battery system, playing a vital role in the vehicle’s range and safety. This study takes the battery pack of an electric vehicle as a subject, employing advanced three-dimensional modeling technology to conduct static and dynamic analyses. Through weight reduction and structural optimization, an innovative power battery pack design scheme is proposed, aiming to achieve a more efficient and lighter electric vehicle power system. The main research tasks are as follows: Firstly, we designed the main load-bearing components of a certain electric vehicle’s power battery pack and established a three-dimensional (3D) model. Then, the model was simplified according to the actual stress conditions of the power battery pack of the electric vehicle and imported into finite element analysis (FEA) software. Next, based on the fundamental principles of the finite element method (FEM), we conducted static analyses under three conditions: bumpy road sharp left turn, bumpy road sharp right turn, and bumpy road emergency braking. The analysis results indicate that the strength of the battery pack meets the allowable requirements, suggesting that the lower housing design has significant redundancy, providing guidance for subsequent optimization. Finally, through modal analysis, we extracted the first six modes of the power battery box, with the first mode frequency being 33.69 Hz. This suggests that the battery pack may experience resonance during actual operation. Based on the static and modal analysis results, we proposed a structural optimization and lightweight design solution for a certain electric vehicle battery pack and compared it with the pre-optimization data.