Lightweight design of the battery swap box for a heavy-duty new energy commercial vehicle
ZHU Xiuwen
LI Wei
ZHANG Dongjiang
ZHOU Shuai
WANG Tong
Abstract：In order to solve the problem of excessive mass of the battery swap box for heavy-duty trucks,the framework of the battery swap box for a certain heavy-duty pure electric commercial vehicle is lightweight under the premise of ensuring reliability and safety.The constraint mode,static strength and deformation of the lightweight battery swap box are analyzed by finite element method,and verified by vibration test and full vehicle reinforcement bad road test.The analysis results show that after lightweight design,the mass of the battery swap box is reduced from 735 kg to 426 kg,the first order modal frequency of the improved battery swap box is 12.24 Hz,which meets the requirement of modal frequency greater than 10.00 Hz,the safety factor of the four typical working conditions of emergency braking,right emergency turning,upward jolting and battery swapping lifting are 2.18～3.19,all exceed 1.25,and the static strength meets the design requirements.The maximum deformation of the battery swap box under the four working conditions is 5.90 mm,which meets the requirement of enterprise technical standards.The results of the bench test and the bad road test show that appearance of the battery swap box is intact without any signs of damage,meeting the requirements for use.
Keywords：lightweightbattery swap boxload spectrum collectionfinite element analysisvehicle testing
Publication Date：2025-01-30
Online Publishing Date：2026-05-22(First online date of this platform, not the publication date of the document)
Pages：7( 80-86 )