CAE-Based Lightweight and Structural Optimization of a Battery Frame for Pure Electric Heavy-Duty Trucks

Bin Chen; Meng Tang; Xiangli Lu

doi:10.48084/etasr.18536

Authors

Bin Chen School of Mechanical Engineering, Hunan Mechanical & Electrical Polytechnic, Changsha, China
Meng Tang School of Mechanical Engineering, Hunan Mechanical & Electrical Polytechnic, Changsha, China
Xiangli Lu School of Mechanical Engineering, Hunan Mechanical & Electrical Polytechnic, Changsha, China

Volume: 16 | Issue: 3 | Pages: 36097-36102 | June 2026 | https://doi.org/10.48084/etasr.18536

Received: 5 March 2026 | Revised: 6 April 2026 | Accepted: 17 April 2026 | Online: 6 June 2026

Corresponding author: Meng Tang

Abstract

Pure-electric heavy-duty trucks require lightweight, reliable battery frames to improve payload capacity and operational efficiency. In this study, a battery frame for a pure electric heavy-duty truck was optimized using a Computer-Aided Engineering (CAE)-based design methodology. Static strength and modal analyses were first performed to identify structural redundancy and stiffness deficiencies. Based on these results, a comprehensive optimization strategy integrating topology optimization, size optimization, aluminum alloy material substitution, and CAE verification was applied to the upper frame, base tray, subframe, and connecting components. The optimized battery frame achieves 164 kg mass reduction, corresponding to 24% lightweight rate, while meeting strength and stiffness requirements across all critical working conditions. The maximum deformation is reduced by 41%, and the first-order natural frequency increases by 28.8%, effectively avoiding resonance within typical road excitation frequency ranges. The results demonstrate significant improvements in both static and dynamic performance, indicating the effectiveness of the proposed optimization strategy. Physical safety performance tests are planned to further validate the feasibility and engineering applicability of the optimized design.

Keywords:

CAE simulation, lightweight optimization, topology optimization, pure electric heavy-duty truck

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