Design Optimization and Experimental Validation of a Multipurpose Mounting Bracket for Electric Vehicles

Abstract

In electric vehicles, the optimal positioning of components and dedicated space for the battery pack are crucial. To address this, we developed a multipurpose bracket designed to save space by holding both the air compressor tank and the spare wheel. We conducted static analysis under various load conditions to ensure robustness. A significant challenge was choosing a mount location for the bracket, as the air compressor tank supplies air to the brakes, necessitating careful consideration of routings. This new bracket replaces two existing brackets into one made of steel, that is feasible for manufacturing. This work involved modelling the bracket and simulating various load cases, including static, shock, braking, and cornering, using Altair Hyper Mesh to evaluate strength and durability. A baseline model is initially designed, followed by thickness reduction and topology optimization to minimize weight and prevent overdesign. After optimization, a new bracket was modelled, and analysis was reiterated. Additionally, modal analysis was performed to obtain natural frequencies and mode shapes. Physical validations using strain gauges for various road events were conducted to correlate the results, showing good agreement. As a result, a lightweight, robust mounting bracket that meets strength and durability requirements was successfully developed, allowing the saved space to be utilized for the auxiliary battery pack.