Topology optimization of power battery cabin in electric vehicle

A new methodology for the electric vehicle (EV) power battery cabin design was presented based on the topology optimization. In the modeling of topology optimization, the variable density method was used on the basis of the SIMP (solid isotropic material penalization) based interpolation function. In the topology optimization for the power battery cabin of a certain EV, taking the cabin manufacturability into account, a structure model of the optimized battery cabin was built. The optimized structure was compared with the conventional structure using the finite element analysis to ensure the reliability of the new structure. The numerical instability in the topology optimization was avoided effectively by controlling the structure minimum size and mesh size. The battery cabin designed by the proposed topology optimization method is lighter in mass than the conventional structure at the equivalent mechanical strength. The stress distribution in the new structure appears more uniform, it is superior in realization of iso-strength design.