Integrated Design and Analysis of a Battery Mounting Bracket Tray in Four-Wheelers

The rapid expansion of electric vehicles (EVs) necessitates continuous advancements in their components to improve performance, safety, and efficiency. This paper presents a comprehensive study on the optimization design and analysis of battery brackets specifically tailored for electric vehicles. Battery brackets are critical components that secure the battery pack, impacting both vehicle safety and battery performance. This research focuses on optimizing the design of a battery bracket to achieve maximum structural integrity while minimizing weight. A comprehensive design process were employed, incorporating finite element analysis (FEA) and topology optimization techniques using ANSYS. Initially design will be created using Solid works 2022 and then FEA analysis will be perform to evaluate the bracket's stress distribution, deformation, and safety factors under loading conditions. Topology optimization were used to identify optimal material distribution within the bracket, maximizing stiffness and strength while minimizing mass. The optimized battery bracket design will validate through experimental testing using universal testing machine and compared to the initial design. The results demonstrated significant improvements in terms of weight reduction, stress distribution, and safety factors. The methodology and findings can be applied to the development of safer, more efficient, and cost-effective electric vehicles.