Body Structure Design and Fabrication of a Five-seat Electric Vehicle

• Main Authors: Syu, Fong-Jie, 許峰玠
• Other Authors: Chen, Yung-Chuan
• Format: Others
• Language: zh-TW
• Published: 2016
• Online Access: http://ndltd.ncl.edu.tw/handle/03283566479303225355

碩士 === 國立屏東科技大學 === 車輛工程系所 === 104 === In this thesis, the lightweight design analysis process for an electric vehicle body structure with five seats is proposed. The lightweight analysis process combines topology optimization analysis and finite element model analysis. The design weight of the body structure is set to be less than 200 kg.The bending stiffness and the torsional stiffness of the body structure are design to be greater than 4000 N/mm and 2000 N.m/deg, respectively. In this research, the Hyperwork topology optimization software is used for the lightweight analysis of the body structure. Three dimensional finite element models are proposed for modal analysis,stiffness,strength,collision, and fatigue life analyses of the body structure using the commercial finite element software ABAQUS. The results indicate that the weight of the proposed body structure is 180 kg according to the lightweight design analysis process. The first bending frequency of the body structure is 26.5 Hz. The bending stiffness and the torsional stiffness of the body structure are 4310 N/mm and 2198 N.m/deg, respectively. A collision simulation has been made at the speed of 40km/hr. The results show that the vehicle longitudinal shrinkage deformation of the body structure is 451 mm. The shrinkage deformation of footwell area is 95mm. The results obtained from the collision analyses also show that the proposed body structure can satisfy the required specifications of European Union ECE R94 and ECE R95. The simulation results show that the fatigue life of the body structure is reduced as the road roughness level increases. In this study, the fatigue lives of the proposed body structure are 6.76×1010,1.31×107,1.21×103and1.5×101 under the conditions of the road level A,B,C and D, respectively.