Design and analysis of a light electric vehicle

This paper discusses a systematic vehicle design process in which light weight is taken as the vehicle design objective, and the designed frame is analyzed in detail. The load condition of a vehicle under different circumstances is calculated according to the distances from the front and rear wheels to the centroid position. The stress on the components in the condition is analyzed by finite element analysis, the steering geometry of the vehicle is analyzed, and the vehicle's turning angle and radius are designed. The displacement of the vehicle under a load is calculated by rigidity analysis to determine the stability of the vehicle in motion. The experimental modal analysis of the real frame and the finite element method are verified mutually for the electric vehicle body-in-white (BIW) manufacturing process to determine the consistency of model formation and the real frame. In terms of the circuit design, we used no-fuse switches and fuses to provide overcurrent protection for the main power supply, and the chip is combined with an optically coupled circuit and current sensor, which is driven by a restriction controller for protection. Moreover, a solid-state relay (SSR) is used for current protection and for controlling the forward/reverse rotation of the motor.

Automated summary

This study systematically discusses a vehicle design process with lightweight as the design objective, focusing on the analysis of the designed frame. The research calculates the load condition of the vehicle under different circumstances, analyzes the stress on components, and designs the steering geometry, turning angle, and radius. Rigidity analysis and finite element analysis are used to determine the stability of the vehicle in motion, while experimental modal analysis and finite element method are mutually verified to ensure consistency between the model formation and the real frame in the electric vehicle manufacturing process. In terms of circuit design, overcurrent protection is provided for the main power supply using no-fuse switches and fuses, and a combination of chip, optically coupled circuit, current sensor, and restriction controller is used for further protection and control.