Lightweight design of battery box for electric vehicle

Aiming to the lightweight design of the battery box for electric vehicle, this paper research the design process and the strength analysis method of long carbon fiber reinforced thermoplastic (LCFT) for a battery box of a sanitation vehicle. First, the box's basal body structure is obtained base on static loading state, the safety margin optimization is conducted to structure the lightest weight and highest performance laminated plates. Second, building strengthen structure in order to improve the ability of under dynamic load, as the unexpected situations may happen when driving a vehicle, such as frontal impact, side impact, dropping collision, and the robust structure of box with reinforcing rib of the long carbon fiber reinforced thermoplastic (LCFT) is obtained. In order to check the safety performance of the battery box under static or dynamic loads, by using ABAQUS finite element software. Third, to avoid the resonance with chassis parts by using topography optimization method, optimization results show that the improved structure not only satisfy the requirement of the dynamic and static load bearing and inherent frequency. The lifting lug of metallic insert molded-in is another typical feature in order to improve connection stiffness for box. The analysis results show that the battery box saves about 42% weight compared to the aluminum alloy. The methods and consideration in this paper may also provide some ways to design and strength analysis for composite material components that meet the requirement of automotive lightweight.