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This study investigates the structural integrity and dynamic behavior of symmetry-optimized battery pack systems for new energy vehicles through advanced finite element analysis. It examines symmetry-optimized battery pack systems with mechanically stable and thermally adaptive potentials. Leveraging geometric symmetry principles, a high-fidelity three-dimensional (3D) model was constructed in SolidWorks 2023 and subjected to symmetry-constrained static analysis on ANSYS Workbench 2021 R1 platform. The structural performance was systematically evaluated under three critical asymmetric loading scenarios: emergency left/right turns and braking conditions, with particular attention to symmetric stress distribution patterns. The numerical results confirmed the initial design’s compliance with mechanical requirements while revealing symmetric deformation characteristics in dominant mode shapes. Building upon symmetry-enhanced topology configuration, a novel lightweight strategy was implemented by substituting Q235 steel with ZL104 aluminum alloy. While mechanical symmetry has been widely studied, thermal gradients in battery packs can induce asymmetric expansions. For example, uneven cooling may cause localized warping in aluminum alloy shells. This multiphysics effect must be integrated into symmetry constraints to ensure true stability. Symmetric material distribution optimization reduced the mass by 19% while maintaining structural stability, as validated through comparative static and modal analyses. Notably, the symmetric eigenfrequency arrangement in optimized modules effectively avoids common vehicle excitation bands (8–12 Hz/25–35 Hz), demonstrating significant resonance risk reduction through frequency redistribution. This research establishes a symmetry-driven design paradigm that systematically coordinates structural efficiency with dynamic reliability, providing critical insights for developing next-generation battery systems with balanced performance characteristics.
Details
Finite element method;
Risk management;
Performance evaluation;
Optimization techniques;
Electric vehicles;
Topology;
Structural steels;
Energy;
Outdoor air quality;
Killed steels;
Impact strength;
Symmetry;
Stress distribution;
Efficiency;
Design techniques;
Asymmetry;
Design optimization;
Carbon fibers;
Structural integrity;
Temperature gradients;
Working conditions;
Resonant frequencies;
Weight reduction;
Automobile industry;
Finite element analysis;
Performance characteristics;
Constraints;
Aluminum base alloys;
Structural stability
; Liu Chenxing 2 ; Tan, Jianwei 2 ; Tian Guangdong 3
1 School of Mechanical Engineering, Shandong Huayu University of Technology, Dezhou 253034, China; [email protected]
2 National Lab of Auto Performance and Emission Test, School of Mechanical and Vehicular Engineering, Beijing Institute of Technology, Beijing 100081, China; [email protected]
3 School of Mechanical-Electronic and Vehicle Engineering, Beijing University of Civil Engineering and Architecture, Beijing 100044, China; [email protected]