New Energy Vehicle Power Battery Box Structure Design And Plastic Pressure Riveting Connection Performance Research

With the continuous development of electric vehicle related technologies and the advantages of electric vehicles compared with traditional fuel vehicles,such as energy saving and environmental protection,electric vehicles are increasingly favored by consumers.In order to continue to meet the increasing performance requirements of consumers for electric vehicles,the electric vehicle industry needs to continuously improve the overall performance of electric vehicles to enhance their attractiveness and competitiveness.Among them,the battery box is one of the key factors affecting the overall performance of electric vehicles.This performance can not only play a role in protecting the power system,but also have a profound impact on the safety and comfort of the vehicle.For this reason,a battery box is used to study the following aspects:(1)Firstly,based on literature research,the requirements of battery box design and the layout of common boxes and modules were described.Then,the 3d modeling of battery box was carried out in UG,and the finite element model was established by the mesh division of the battery box through Hypermesh.to optimize the overall performance of the box,reduce the weight of the box,increase the energy density of the power system and improve the stiffness of the upper box,Optistruct software was used to optimize the appearance of the original upper box and the size of the original lower box respectively.(2)Then,considering the problem of excessively long welding seam when aluminum alloy box is connected by CMT and other technologies,to reduce the number of battery box to reduce the aluminum alloy weld box production cost efficiency,this paper draw lessons from the mortise and tenon joint structure of plastic pressure riveting connection section design,final design out many plastic pressure riveting connection to promote reduce weld connection between aluminum alloy material performance.(3)What’s more,to verify the feasibility of plastic pressure riveting to improve the connection performance,the designed plastic pressure riveting connection was carried out in the three point bending test and the simulation analysis,and then the differences in the connection performance between CMT welding and plastic pressure riveting in the three point bending test were compared.At the same time,to ensure theaccuracy of the finite element simulation of the plastic riveting connection,the results of the plastic riveting test and the simulation analysis are compared to verify that the simulation analysis can accurately reflect the mechanical properties of the plastic riveting connection.The results show that although the plastic riveting connection can effectively improve the connection performance between the box materials,it still has a certain gap compared with the traditional welding.Therefore,the CMT welding process and the plastic riveting connection technology should be combined for the connection between the battery box materials to finally improve the box connection performance and reduce the weld length.(4)Subsequently,The static analysis and modal analysis of typical working conditions of the new battery box that has been optimized in shape and size,and connected with plastic pressure riveting are performed to verify that the optimized battery box meets the design requirements of the box.In order to further verify that the plastic pressure riveting connection can improve the overall performance of the battery box,longitudinal extrusion simulation analysis of the new battery box with plastic pressure riveting and without plastic pressure riveting is performed respectively.The plastic pressure riveting connection box is more resistant to deformation in longitudinal extrusion simulation analysis,so the plastic pressure riveting connection can effectively improve the safety of the box body in a side collision accident.(5)Finally,according to the requirements of the national standard for random vibration fatigue life,random vibration fatigue life performance analysis was carried out on the optimized box with plastic riveting and without plastic riveting.The fatigue life analysis results showed that the plastic pressure riveting connection can not only effectively improve the battery box Body connection performance,and can improve the fatigue life of the battery box,which has a significant improvement effect on the fatigue life of the box,so the plastic pressure riveting connection to the battery box has certain engineering practical value,at last,through the box sample manufacturing test,further verify that the designed box meet the requirements of various regulations.