关键词: 新能源轻卡；车架总成；电池支架总成；集成化

Abstract: New energy light-duty trucks commonly employ a single-pack battery configuration mounted beneath the chassis frame. In accordance with current design requirements, the chassis must undergo structural reinforcement in the battery installation area to withstand concentrated impact loads. Simultaneously, the battery brackets must fulfill the dual functions of supporting the battery weight and connecting to the chassis, resulting in increased strength requirements for both the chassis assembly and the battery bracket assembly. This leads to elevated component weight and costs. To address this, an integrated design approach for the chassis assembly and battery bracket assembly has been proposed. Through structural design and optimization, a lightweight solution is developed to reduce weight and cost. Computer aided engineering (CAE) analysis confirms that, without compromising assembly stiffness and strength, a lightweight reduction of approximately 10.5% and a cost reduction of about 11.6% have been achieved. Additionally, two upper battery brackets have been eliminated, and production processes have been streamlined. This study provides a novel development strategy for new energy light-duty truck chassis and battery brackets, delivering both energy efficiency benefits and enhanced cargo space for users.

Key words: new energy light truck; frame assembly; battery bracket assembly; integration