基于VRB/OW-GFRP混合结构的CTB电池包上盖总成轻量化设计研究  

Research on Lightweight Design of CTB Battery Pack Cover Assembly Based on VRB/OW-GFRP Hybrid Structure

作　　者：段利斌 张雨 杜展鹏 刘冶钢 孟祥新[2] 田冠男[2] 郑海洋 吴闯 Duan Libin;Zhang Yu;Du Zhanpeng;Liu Yegang;Meng Xiangxin;Tian Guannan;Zheng Haiyang;Wu Chuang(School of Automotive and Traffic Engineering,Jiangsu University,Zhenjiang 212013;Chery Automobile Co.,Ltd.,Wuhu 241006)

机构地区：[1]江苏大学汽车与交通工程学院,镇江212013 [2]奇瑞汽车股份有限公司,芜湖241006

出　　处：《汽车工程》2024年第2期290-299,共10页Automotive Engineering

基　　金：国家自然科学基金(52275252);江苏省重点研发计划项目(BE2022053-4)资助。

摘　　要：电池车身一体化(CTB)是提升电动汽车续航里程的关键技术。利用胶接工艺将变厚度(VRB)结构与正交编织玻璃纤维增强复合材料(OW-GFRP)粘接形成的VRB/OW-GFRP混合结构,是降低CTB电池包质量的创新结构,有助于进一步提升电动汽车的续航里程。以某款电动汽车为研究对象,设计了一种CTB电池车身一体化结构,实现了电池包上盖与车身地板的集成融合。分别采用VRB结构、UT/OW-GFRP及VRB/OW-GFRP混合结构替代等厚度(UT)CTB电池包上盖总成,并基于多阶段优化方法开展了3种类型CTB电池包上盖总成的轻量化设计。结果表明,在满足CTB电池包刚度性能前提下,VRB结构相比UT结构实现减质量6.4%;基于VRB/OW-GFRP混合结构的CTB电池包上盖总成轻量化效果约为金属结构的3倍,VRB/OW-GFRP相比UT/OW-GFRP混合电池包上盖总成进一步减质量4.2%。由此可见,VRB/OW-GFRP混合结构是未来汽车轻量化技术发展的重要趋势,在CTB电池包上盖总成中具有巨大的应用前景。Cell to body(CTB)is a key technology to improve the endurance mileage of electric vehicles.The VRB/OW-GFRP hybrid structure formed by the variable-thickness rolled blanks(VRB)structure and the ortho⁃tropic woven GFRP(OW-GFRP)through the bonding process is an innovative structure,which can reduce the weight of the CTB battery pack,thus improve the endurance mileage of electric vehicles.Taking an electric vehicle as the research object,a CTB battery body integrated structure is designed to realize the integration of the upper cov⁃er of the battery pack and the floor of car body.Furthermore,the cover assembly of the uniform thickness(UT)CTB battery pack are replaced by the VRB structure,UT/OW-GFRP and VRB/OW-GFRP hybrid structure.The light⁃weight design of the upper cover assembly of the three types of CTB battery pack are carried out based on the multistage optimization method.The results show that the weight of VRB structure is reduced by 6.4%compared with that of UT structure when the stiffness performance of the CTB battery pack is met.The lightweight level of the upper cov⁃er assembly of the CTB battery pack based on the VRB/OW-GFRP hybrid structure is about three times that of the GFRP hybrid battery pack upper cover assembly.Thus,the VRB/OW-GFRP hybrid structure is the inevitable trend of the development of automotive lightweight technology in the future,showing a great application prospect in CTB battery pack cover assembly.

关 键 词：变厚度/正交编织玻璃纤维增强复合材料 混合结构 电池车身一体化 电池包 轻量化 

分 类 号：U469.72[机械工程—车辆工程]