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

摘要： 新能源轻卡车型普遍采用单包电池配置，安装在车架腹部，按照目前设计要求，车架 需在电池安装区域进行结构强化，以承受集中载荷冲击，同时电池支架需要满足承载电池质 量和连接车架的作用，导致车架与电池支架总成各自强度增强，零件质量和成本增加。由此， 提出将车架总成与电池支架总成进行集成化设计开发，经过结构设计和优化，对其进行轻量 化设计并降本，经过计算机辅助工程（CAE）分析，在不降低总成刚度和强度的前提下，实 现轻量化约 10.5%，降成本约 11.6%，且减少两个电池上支架并优化生产工艺。该研究为新能 源轻卡车架与电池支架开发提供新思路，既节能又为用户提供装载空间。

关键词: 新能源轻卡；车架总成；电池支架总成；集成化