Abstract: Regarding the cracking problem of the internal tab of a certain heavy-duty truck battery during the durability test, this article conducts a cause investigation from three aspects: wire harness pulling, layout position influence, and vibration fatigue. Through finite element simulation methods, using the actual vehicle acceleration load at the installation points of the battery frame, based on the damage equivalent method, the power spectral density (PSD) load is obtained for the analysis of relative deformation of the wire harness, the random response analysis of the battery with different layouts, and the vibration fatigue simulation analysis of the battery structure. The cracking cause is identified. At the same time, the influence of different factors on vibration fatigue is discussed, to guide the design confirmation optimization scheme. The final optimization scheme is verified by the actual vehicle, proving the effectiveness of the cause investigation and simulation verification in the article, providing ideas and references for the structural design development and durability performance simulation analysis of the battery.

Key words: battery; random response; vibration fatigue; structural optimization

摘要： 针对某重卡蓄电池内部极耳在耐久试验中出现的开裂问题，文章从线束拉扯、布置位 置影响以及振动疲劳三方面进行了原因排查。通过有限元仿真手段，利用蓄电池框架安装点的 实车加速度载荷，基于损伤等效的方法，获取功率谱密度（PSD）载荷，用于线束相对变形 分析、蓄电池不同布置的随机响应分析及蓄电池结构的振动疲劳仿真分析，锁定开裂原因。 同时展开讨论了不同因素对振动疲劳的影响，用于指导设计确认优化方案，优化方案最终通 过实车验证，证明了文章的原因排查及仿真验证的有效性，为蓄电池的结构设计开发及耐久 性能仿真分析提供思路和参考。

关键词: 蓄电池；随机响应；振动疲劳；结构优化