Lightweight design of new energy vehicle power battery pack based on finite element simulation and optical detection

This study conducts research on the lightweight design of new energy vehicle power battery packs based on the finite element analysis method. Firstly, a numerical model of the battery pack was established using the ANSYS Workbench platform for coupled static and modal analysis, revealing its stress field distribution under composite conditions of emergency braking (Condition 1) and sharp turning (Condition 2), with a maximum stress of 143.15 MPa and a fundamental frequency (the first of the initial six natural frequencies) of 17.095 Hz. Subsequently, material substitution designs using aluminum alloy and high-strength SMC were adopted, and the feasibility of the lightweight solution was verified through multiphysics simulation and optical detection technology. The results show that the high-strength SMC solution achieved a 76% mass reduction while increasing the fundamental frequency to 38.536 Hz; the maximum working stress of 33.73 MPa remained below the material's yield strength of 80 MPa, effectively avoiding the risk of resonance in typical road excitation frequency bands. This study provides a material-structure synergistic optimization paradigm for the lightweight design of power battery systems.