Internal structure layout and optimization design of FSEC racing power battery box

doi:10.19799/j.cnki.2095-4239.2020.0141

Abstract

Abstract:

In Formula Student Electric China (referred to as FSEC), the power battery box is the core of the car and its internal structural layout and design are very important. Based on selecting the new box material, Simulink was used to simulate the power system of the racing car to determine the capacity of the battery module, followed by the use of CATIA to accurately model the internal components of the racing car power battery box and to analyze the heat generation and heat dissipation of the battery box through ANSYS. Finally, CATIA battery box was manipulated to carry out the overall design and optimize the internal layout. The strength, heat dissipation, power, and durability of the finished battery box were tested to verify the effectiveness of the design. Based on ensuring the heat dissipation efficiency, reliability, and safety of the power battery system, the layout of the internal structure of the power battery box are improved through exploiting the above procedures so that the space utilization rate of the power battery box is greatly improved and the group efficiency of the battery pack reaches 0.723; realizing the lightweight design of the power battery pack and even the whole vehicle.

Key words: power battery box, FSEC, power battery system, structural design, lightweight

CLC Number:

U 469.72+2

Jian SHEN, Bixiong HUANG, Zhaokang XIE, Jiayin LI, Ningning LIU, Zhiqiang JIA. Internal structure layout and optimization design of FSEC racing power battery box[J]. Energy Storage Science and Technology, 2020, 9(S1): 31-38.

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项目	参数
电池单体额定容量	18 A·h
最高电压	4.2 V
额定电压	3.7 V
最小电压	3.0 V
最大输出电流	540 A
最大充电电流	270 A
电池单体最高温度(未充电时)	60 ℃
电池单体最高温度(充电时)	45 ℃
电池单体的化学物质	钴酸锂

项目	参数
最大电压	453.6 V
额定电压	399.6 V
最低电压	324 V
最大输出电流	540 A
最大充电电流	90 A
电池单体总数	108
电池模组连接形式	螺栓连接
总容量	7.1928 kW·h
电池模块数量	6块

零部件名称	材料	数量 /个	长度 /mm	宽度 /mm	高度 /mm	厚度/mm	施加载荷/Pa		承载最大应力/Pa	最大变形位移/mm	是否合格
零部件名称	材料	数量 /个	长度 /mm	宽度 /mm	高度 /mm	厚度/mm	水平方向	竖直方向	承载最大应力/Pa	最大变形位移/mm	是否合格
底板	铝合金	1	495.4	330.4	—	3.2	—	6.47×10³	5.47×10⁶	6.69×10^-2	是
箱体	铝合金	1	500	335	237.7	2.3	1.38×10⁴	—	4.57×10⁷	1.5	是
箱盖	铝合金	1	504.6	339.4	—	2.3	—	7.33×10³	1.21×10⁷	4.33×10^-1	是
固定支架	铝合金	10	20	20	20	3.2	4.38×10⁶	—	2.96×10⁵	2.51×10^-4	是
固定支架	铝合金	10	20	20	20	3.2	—	3.42×10⁶	8.44×10⁴	2.11×10^-5	是
吊环	铝合金	3	50	40	—	3.2	—	1.38×10⁵	8.93×10⁶	1.61×10^-2	是
电池箱	铝合金	1	500	335	240	—	—	—	—	—	是

材质	Q235钢	碳纤维/环氧树脂复合材料
最大应力/MPa	73.1	81.0
应力集中区域	电池箱底部中心	电池箱底部中心
最大形变/mm	1.22	1.63
主要变形位置	电池箱底部中心	电池箱底部中心
电池箱质量/kg	35.2	12.4
减轻质量/%	0.64	—

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