Analytical Analysis of Electric Vehicle Chassis Frame and Battery Thermal Management System

Abstract

AbstractThe energy stored in the battery is the source of the energy to drive the electric vehicles. At the moment the size and the weight of the battery pack required for given mileage are very much high when compared to its counterpart IC engine. The main aim of this work is to modify the existing electric vehicle chassis frame for giving the provision of swapping battery rather than having permanent battery pack on the chassis frame. Specifically by taking RAV4 V5 EV as a baseline and all analysis was done on it, the static, dynamic and static impact (crush analysis) on finite element (ANSYS) is performed, battery thermal management system in the transient analysis by using EXCEL and ANSYS FLUENT is identified, and finally, prototype fabrication is carried out to demonstrate the shape of the chassis frame. According to study, the Material AISI 1020 and rectangular cross-section in 80 mm × 40 mm × 4mm is selected to the electric vehicle chassis frame and the modelling was done by using CATIA V5 and the analysis using ANSYS. Finally, the total deformation of chassis frame is 1.007 mm, equivalent stress is 115.88 MPa and the life of the chassis on full load is 130 days without deformation. The weight of the electric vehicle battery pack is decreased from 383.51 kg to 345.615 kg by modification of existing cooling plate and the chassis frame has a longer life than previous design because of the weight minimization of the battery pack on the existing vehicle.KeywordsBatteries packChassis frameElectric vehicleSwapping and BTMS