Electric Bus Body Structural Lightweight Design And Research

Electric passenger car’s shorter mileage and less power are restricted to promote their application technical obstacle. Reduce the total quality of electric bus to extend its range, increase its power, enhance the power is very important. While the electric bus body frame as the main bearing components of electric bus, electric bus for total mass percent maximum, so the electric bus body frame lightweight research on reducing electric passenger car general quality is very important.This paper takes a bus company research and development of pure electric bus body skeleton of GZ6100EV as the research object, using the Finite Element Method in the analysis of "electric bus body structural light-weighting design and research "field study was carried out the following work:1) On the vehicle body skeleton structure simplification. Using CATIA-V5software to establish the skeleton’s three-dimensional modeling and then import the entity model into ANSYS Workbench to establish the project.2) Basing on the finite element analysis model, according to the city bus driving cycle, such as bending, torsion, emergency turning and emergency braking which all are dangerous working conditions of body structural, strength and rigidity analysis, get the body in various conditions of stress and strain distribution, analysis of the defects in the former design margin, as a lightweight optimization scheme is proposed to provide the necessary basis;3) According to the finite element analysis results are presented for two lightweight scheme, one is to maintain the original car material constant, use ANSYS-Workbench software platform on body frame design of topology optimization; two is the widespread adoption of advanced high strength steel (AHSS) instead of the original vehicle design in the use of ordinary carbon steel, the structure of the cross section parameter as a variable lightweight design.The study found that the widespread adoption of AHSS, body weight loss effect is more obvious. In this paper, through calculation and analysis, in satisfies the condition of strength and stiffness requirements, use of topological optimization scheme finally the body framework of total quality falls from2140.7Kg to2018Kg, weight loss rate of5.7%, and the widespread adoption of advanced high strength steel, the body frame of total mass is decreased from2140.7Kg to1813.2Kg, reduce327Kg, weight loss high amplitude up to15.27%.It can thus be predicted in the AHSS production technology and processing technology was a breakthrough, the widespread adoption of AHSS will be the realization of body frame lightweight most main way.