Study on lightweight optimization of battery pack box structure for electric vehicle

Abstract A lightweight optimization design process for the battery pack box body of the electric vehicle is proposed based on the lightweight and performance indicators of the battery pack box body. The compression, mode, and strength working conditions of the original design battery pack are analyzed using HyperWorks software. According to the lightweight optimization design process of the battery pack box body, topology optimization and morphology optimization methods are used to improve the performance and lightweight optimization of the typical extruded aluminum profiles and plates of the original design battery pack box body. After optimization, a weight reduction of 2.76 kg is achieved. At the same time, the strength, mode, stiffness and other performance of the battery pack box body meet the requirements of the indicators. The lightweight solution for the battery cover has been put into mass production application.