Performance analysis on the structure of the bracket mounting for hybrid converter kit: Finite-element approach

Abstract

An electric motor mounting bracket is used in electric vehicles, especially hybrid ones using a parallel hybrid configuration. This study aims to analyze the strength and performance of the initial design and topology optimized design. This study uses the finite-element method (FEM) in the bracket design modeling by applying topology optimization. The topology optimization results show a mass reduction of 50% from the initial design mass. In the case of static loading, the results of optimized design 2 have a stress of 142.19 MPa and a safety factor of 3.09. While optimized design 1 has a stress of 313.8 MPa and a safety factor of 1.4. In terms of dynamic loading, the initial design, optimized design 1, and optimized design 2 have the first natural frequency, which is higher than the operating frequency of the electric motor, respectively, 100.49, 69.043, and 74.864 Hz. Optimized design 1 has the lowest natural frequency and the highest amplitude compared to the initial design, and optimized design 2 has lower damping characteristics. The study results conclude that optimized design 2 is superior in static and dynamic loading.

Keywords

• hybrid electric vehicle
• finite-element method
• bracket
• topology optimization