Optimization Design of Upper Mounting Bracket in Engine Compartment of Certain Electric Vehicle
The use of square tube welding in the early stage of the development of the upper mounting bracket in the engine compartment of certain electric vehicle,which reduces the cost of mold development for the crossbeam.However,the welding process is poor,resulting in the weld position is prone to cracking failure mode.In this regard,the crossbeam needs to be welded with a frame connecting plate,but a large number of related parts and is relatively heavy,which does not conform to the trend of lightweight design in automobiles.In order to obtain a high-performance and low-cost upper cabin installation bracket,it is proposed to optimize the design of the upper cabin installation bracket.Firstly,conventional sheet metal stamping process is used to symmetrically design the front and rear crossbeams,and the middle connecting beam parts are shared to reduce the number of parts and mold development.Secondly,the frame connection plate is removed and integrated into both ends of the front and rear crossbeams.Through bolt avoidance and stress transition zone design,weight reduction and fatigue resistance strength are achieved;The upper bracket of the cabin is used to install components such as power control unit(PCU)water pumps,motor controllers,electric air conditioning compressors,and high-voltage distribution boxes.It is usually installed with a combination of round and long holes,which requires the original square tube structure uses high-cost laser cutting holes.In addition,the square tube structure required longer welding bolts to be arranged,and the hollow cavity would also have torque attenuation problems,which need to be solved before mass production.The optimized upper mounting bracket of the cabin adopts sheet metal stamping forming parts,which achieves the goal of cost reduction and weight reduction while meeting the strength requirements.This upper mounting bracket in the engine compartment optimize design can also serve as a reference for similar products.
upper mounting bracket in the engine compartmentoptimize designlightweight
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