Electric vehicle charging port area design method and system

Abstract

The invention relates to the field of electric vehicle design, in particular to an electric vehicle charging port area design method and system, which comprises the following steps: selecting a body-in-white structure unit corresponding to a charging port area, and arranging a rigid structure on the body-in-white structure unit corresponding to the charging port; loading force generated when the charging gun is inserted into and pulled out of the charging port is obtained and applied to the rigid structure, and stress deformation displacement between the rigid structure and the body-in-white structural unit and the residual deformation value of the body-in-white structural unit are recorded so that the structural design of the charging port area can be updated. The charging port is simulated by the rigid structure, the charging port area is simulated by the body-in-white structure unit, the loading force is applied to the rigid structure, the plugging of the charging gun on the charging port is simulated, and the stress deformation displacement and the residual deformation value between the rigid structure and the body-in-white structure unit are calculated. The relative displacement and plastic deformation of the charging port area are analyzed, whether the current structural design is reasonable or not is analyzed, and scientific basis and analysis are provided for the structural design of the charging port area.

Description

Technical Field

[0001] The present application relates to the field of electric vehicle design, and specifically to a method and system for designing an electric vehicle charging port area. Background Art

[0002] Existing technologies have performance requirements for localized vehicle body parts (such as front and rear suspension brackets) and parts attachment points like the brake pedal and battery pack. The design control approach for these areas involves conducting structural design and performance verification based on relevant performance requirements using simulations, four-channel vehicle testing, and RAF (Road Assessment Framework) road tests.

[0003] Currently, there are no performance requirements or design control methods for the charging port area of electric vehicles. Specifically, domestic and international standards have clear performance requirements for the conductive charging connector (the connector is the charging port that connects to the charging gun) for electric vehicles, and there are also mature design verification methods for the design control of conductive charging connectors for electric vehicles. However, these performance requirements and design control only apply to the conductive charging connector itself, and do not address the performance requirements and design control of the vehicle body area where the connector is fixed, that is, the area surrounding the charging port.

[0004] Existing technology relies on long-term road testing or vehicle use after the release of an electric vehicle to identify problems in the area surrounding the charging port (referred to as the charging port area). This is time-consuming and costly to correct. Therefore, there is an urgent need for a quantitative and scientific design control method that can quickly identify performance risks and avoid performance overloads in the early stages of vehicle development, thereby developing an optimal charging port area design. Summary of the Invention

[0005] The present application provides a method and system for designing a charging port area for an electric vehicle, which can solve the technical problem of the lack of design indicators and design verification for the charging port area in the prior art.

[0006] In a first aspect, an embodiment of the present application provides a method for designing an electric vehicle charging port area, the method comprising:

[0007] Select the body-in-white structural unit corresponding to the charging port area, and set a rigid structure at the position corresponding to the charging port on the body-in-white structural unit;

[0008] Obtain the loading force when the charging gun is plugged into or unplugged from the charging port, apply the loading force to the rigid structure, and record the force-deformation displacement between the rigid structure and the body-in-white structural unit, as well as the residual deformation value of the body-in-white structural unit;

[0009] When the stress deformation displacement and the residual deformation values are both greater than the maximum threshold or less than the minimum threshold, the structural design of the charging port area is updated.

[0010] In conjunction with the first aspect, in one embodiment, the method includes:

[0011] Obtaining the body-in-white structural unit and the rigid structure by using a modeling method;

[0012] Finite element analysis is used to apply the loading force to the rigid structure to determine whether the structural design of the charging port area should be updated.

[0013] In conjunction with the first aspect, in one embodiment, the method includes:

[0014] During modeling, multiple welding points are set on the body-in-white structural unit, and the thickness and properties of the multi-layer materials constituting the body-in-white structural unit, as well as the amount and specifications of the glue coating, are set according to the preset standard structural data;

[0015] When conducting finite element analysis, the constraints of the body-in-white structural unit simulate the constraints under the trolley test state, constraining 6 degrees of freedom for the front suspension support of the body-in-white and 6 degrees of freedom for the fixed points of the rear suspension of the body-in-white.

[0016] In conjunction with the first aspect, in one embodiment, the method includes:

[0017] The body-in-white structural member is used as the body-in-white structural unit. A charging port bracket is provided on the body-in-white structural member. An aluminum plate is connected to the charging port bracket as a rigid structure. Rigid tooling is used to fix the body-in-white structural member in the work station.

[0018] When applying the loading force, the loading head of the loading device is used to apply the loading force on the aluminum plate to determine whether the structural design of the charging port area is updated.

[0019] In combination with the first aspect, in one embodiment, the method further includes:

[0020] When applying the loading force to the rigid structure, multiple and multi-angle applications are adopted to obtain multiple sets of force deformation displacements and residual deformation values, and it is determined whether the structural design of the charging port area should be updated based on the multiple sets of force deformation displacements and residual deformation values.

[0021] In combination with the first aspect, in one embodiment, the method further includes:

[0022] When applying a loading force to a rigid structure, the loading force is applied to the center point of the rigid structure.

[0023] In combination with the first aspect, in one embodiment, the method further includes:

[0024] When applying loading force to a rigid structure to calculate the load deformation displacement and residual deformation value, select one of the standard working conditions or special working conditions;

[0025] When the standard working condition is selected, the loading force is obtained based on the insertion force and extraction force of the charging gun on the corresponding vehicle model, as well as the gravity of the charging gun;

[0026] When a special operating condition is selected, the loading force is obtained based on the design value of the connection strength between the charging gun and the charging port on the corresponding vehicle model.

[0027] In combination with the first aspect, in one embodiment, the method further includes:

[0028] When applying the gravity of the charging gun to the rigid structure, the gravity of the charging gun is applied to a preset distance below the center point of the rigid structure.

[0029] In conjunction with the first aspect, in one embodiment, when both the stress deformation displacement and the residual deformation values are greater than a maximum threshold or less than a minimum threshold, updating the structural design of the charging port area specifically includes the following steps:

[0030] When both the stress deformation displacement and residual deformation values are greater than the maximum threshold, the structural design standards of the charging port area are improved;

[0031] When the stress deformation displacement and residual deformation values are both less than the minimum threshold, the structural design standards of the charging port area are lowered.

[0032] In a second aspect, an embodiment of the present application provides an electric vehicle charging port area design system, the electric vehicle charging port area design system comprising:

[0033] A structure selection module, which is used to select a body-in-white structural unit corresponding to the charging port area and set a rigid structure at the position corresponding to the charging port on the body-in-white structural unit;

[0034] The mechanical testing module is used to obtain the loading force when the charging gun is plugged into or unplugged from the charging port. The loading force is applied to the rigid structure, and the force-induced deformation displacement between the rigid structure and the body-in-white structural unit, as well as the residual deformation value of the body-in-white structural unit, is recorded.

[0035] The design analysis module is used to update the structural design of the charging port area when the stress deformation displacement and residual deformation values are both greater than a maximum threshold or less than a minimum threshold.

[0036] The beneficial effects of the technical solutions provided in the embodiments of the present application include:

[0037] This invention proposes performance requirements for the vehicle body in the charging port area of electric vehicles, filling a gap in this area. It also develops a design verification method that allows for efficient and rapid performance verification of the vehicle body in this area. This performance requirement and design verification method are applicable to the design and development of all relevant areas of the vehicle body in electric vehicles. They can quantitatively verify the rationality of the performance design targets for the vehicle body in this area, providing guidance for optimizing the vehicle body structure design in this area and effectively reducing design and development costs as well as after-sales maintenance costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Figure 1 This is a flow chart of an embodiment of a method for designing an electric vehicle charging port area;

[0039] Figure 2 This is a schematic diagram of the loading force in an embodiment of the electric vehicle charging port area design method of the present application;

[0040] Figure 3 This is a schematic diagram of the functional modules of an embodiment of the electric vehicle charging port area design system of the present application. DETAILED DESCRIPTION

[0041] In order to enable those skilled in the art to better understand the present invention, the following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of this application.

[0042] In order to make the objectives, technical solutions and advantages of this application clearer, the implementation methods of this application will be further described in detail below with reference to the accompanying drawings.

[0043] In a first aspect, an embodiment of the present application provides a method for designing an electric vehicle charging port area.

[0044] In one embodiment, referring to Figure 1 and Figure 2 , Figure 1 This is a flow chart of the first embodiment of the electric vehicle charging port area design method of this application. Figure 2 This is a schematic diagram of the loading force in one embodiment of the electric vehicle charging port area design method of this application. Figure 1 and Figure 2 As shown in Figure 1, the design method for the electric vehicle charging port area includes:

[0045] Step S1: Select a body-in-white structural unit corresponding to the charging port area, and set a rigid structure at a position corresponding to the charging port on the body-in-white structural unit.

[0046] Step S2: Obtain the loading force when the charging gun is plugged into or unplugged from the charging port, apply the loading force to the rigid structure, and record the force deformation displacement between the rigid structure and the body-in-white structural unit, as well as the residual deformation value of the body-in-white structural unit.

[0047] Step S3: When the stress deformation displacement and the residual deformation values are both greater than the maximum threshold or less than the minimum threshold, the structural design of the charging port area is updated.

[0048] In this embodiment, a rigid structure is used to simulate the charging port, and a body-in-white structural unit is used to simulate the charging port area. By applying a loading force to the rigid structure, the plugging and unplugging of the charging gun on the charging port is simulated. By calculating the force deformation displacement and residual deformation values between the rigid structure and the body-in-white structural unit, the relative displacement and plastic deformation of the charging port area are analyzed, and the rationality of the current structural design is analyzed, thereby providing a scientific basis and analysis for the structural design of the charging port area.

[0049] This invention proposes performance requirements for the vehicle body in the charging port area of electric vehicles, filling a gap in this area. It also develops a design verification method that allows for efficient and rapid performance verification of the vehicle body in this area. This performance requirement and design verification method are applicable to the design and development of all relevant areas of the vehicle body in electric vehicles. They can quantitatively verify the rationality of the performance design targets for the vehicle body in this area, providing guidance for optimizing the vehicle body structure design in this area and effectively reducing design and development costs as well as after-sales maintenance costs.

[0050] Furthermore, in one embodiment, the method includes:

[0051] The body-in-white structural unit and rigid structure are obtained using modeling methods.

[0052] Finite element analysis is used to apply loading force to the rigid structure to determine whether the structural design of the charging port area should be updated.

[0053] In this embodiment, the finite element method is used to perform static analysis on the body-in-white structural unit in the charging port area. The software used is NASTRAN to simulate the loading force of the charging gun in various postures, that is, the loading force, and calculate the stress deformation displacement and residual deformation value of the body structure.

[0054] Furthermore, in one embodiment, the method includes:

[0055] During modeling, multiple welding points are set on the body-in-white structural unit, and the thickness and properties of the multi-layer materials constituting the body-in-white structural unit, as well as the amount and specifications of the glue coating, are set according to preset standard structural data.

[0056] When conducting finite element analysis, the constraints of the body-in-white structural unit simulate the constraints under the trolley test state, constraining 6 degrees of freedom for the front suspension support of the body-in-white and 6 degrees of freedom for the fixed points of the rear suspension of the body-in-white.

[0057] In this embodiment, when simulating the loading force of the charging gun in various postures and calculating the displacement and residual deformation values under vehicle body structure deformation, the main considerations are as follows:

[0058] The location of weld points in the body-in-white modeling, especially the thickness and properties of multi-layer materials, as well as the amount and specifications of glue.

[0059] The white body constraint simulates the constraint mode under the trolley test state. The front suspension support of the white body constrains 6 degrees of freedom, and the rear suspension fixed point constrains 6 degrees of freedom.

[0060] The charging port is replaced by a rigid unit, and the force acting as a simulated charging gun is loaded on the rigid unit.

[0061] Furthermore, in one embodiment, the method includes:

[0062] The body-in-white structural member is used as the body-in-white structural unit, a charging port bracket is provided on the body-in-white structural member, an aluminum plate is connected to the charging port bracket as a rigid structure, and a rigid tooling is used to fix the body-in-white structural member at the work station.

[0063] When applying the loading force, the loading head of the loading device is used to apply the loading force on the aluminum plate to determine whether the structural design of the charging port area is updated.

[0064] In this example, a representative and mature painted vehicle body was selected and secured with rigid fixtures. A rigid unit simulating a charging port was mounted on the charging port bracket on the vehicle body. Appropriate force-applying equipment was used to load the rigid unit, and the displacement and residual deformation of the vehicle body structure were measured.

[0065] When verifying the body stiffness, the main considerations are as follows:

[0066] ① Select a paint car body that is representative and mature (such as the parts / weld points / glue data and quantity have been solidified, and the car body size / weld points / glue inspection meets the requirements).

[0067] Use rigid tooling to fix the front and rear overhang mounting points of the body in white. The body should not move before and after the loading force is applied (a dial indicator can be installed at a designated position on the body in white, and ensure that the dial indicator is zero before and after each measurement).

[0068] Select an aluminum plate with appropriate thickness (generally >5mm) as the rigid unit of the charging port. The size of the aluminum plate is determined according to the shape of the charging port bracket. Use the charging port fixing holes to fix the aluminum plate to the charging port bracket with bolts.

[0069] Mark the vehicle body displacement measurement point in the charging port area.

[0070] Select appropriate force loading equipment + loading head to load the force, and load each working condition 5 times.

[0071] Use equipment that can measure displacement in three directions of X / Y / Z to measure the displacement measurement points of the vehicle body.

[0072] The verification is carried out on two vehicle bodies: vehicle body 1 undergoes standard working condition test verification, and vehicle body 2 undergoes special working condition test verification.

[0073] Furthermore, in one embodiment, the electric vehicle charging port area design method of the present application further includes:

[0074] When applying loading force to the rigid structure, multiple and multi-angle applications are adopted to obtain multiple sets of force deformation displacement and residual deformation values. Based on the multiple sets of force deformation displacement and residual deformation values, it is determined whether the structural design of the charging port area should be updated.

[0075] In this embodiment, the loading force is offset at a certain angle within the design allowable range: the loading angle direction of the charging gun is simulated, and the extreme offset angle is formulated according to human-machine operation and the opening range of the charging port shell.

[0076] Furthermore, in one embodiment, the method further includes:

[0077] When applying a loading force to a rigid structure, the loading force is applied to the center point of the rigid structure.

[0078] In this embodiment, the center of the rigid structure corresponds to the center of the outer end surface of the charging port, and the loading direction can be customized.

[0079] Furthermore, in one embodiment, the method further includes:

[0080] When applying loading force to a rigid structure to calculate the load deformation displacement and residual deformation value, select one of the standard working conditions or special working conditions.

[0081] When selecting the standard working condition, the loading force is obtained based on the insertion force, extraction force, and gravity of the charging gun on the corresponding vehicle model. Figure 2 As shown in the figure, F1 is the insertion force at an offset of 15°, F2 is the removal force at an offset of 15°, and F3 is the gravity of the charging gun.

[0082] When selecting special working conditions, the loading force is obtained according to the design value of the connection strength of the charging gun and the charging port on the corresponding vehicle model.

[0083] In this embodiment, by organizing research activities, information on the charging gun usage habits of electric vehicle users is obtained, and it is organized and analyzed using scientific and objective methods. The stress conditions of the vehicle body in the charging port area are divided into two working conditions: standard working conditions and special working conditions, and loading force requirements are set for these two working conditions respectively.

[0084] Under standard working conditions, the design requirements for the insertion and extraction force of the charging gun of a specific vehicle model and the gravity of the charging device (weight of the charging gun + charging cable) are used as the loading force.

[0085] Under special working conditions, the design value of the connection strength between the charging gun and the charging port of the specific vehicle model is used as the loading force.

[0086] Both working conditions consider the situation where the loading force is offset at a certain angle within the design allowable range, simulate the loading angle direction of the charging gun, and formulate the extreme offset angle according to human-machine operation and the opening range of the charging port shell.

[0087] To meet the functional requirements of electric vehicle charging, the basic requirements for the body stiffness performance in the charging area are that the body area cannot experience large relative displacement during loading of the charging port area, and after unloading, the body area cannot experience obvious plastic deformation.

[0088] Furthermore, in one embodiment, the method further includes:

[0089] When applying the gravity of the charging gun to the rigid structure, the gravity of the charging gun is applied to a preset distance below the center point of the rigid structure.

[0090] In this embodiment, the required loading force under standard working conditions is shown in Table 1 below, and the required loading force under special working conditions is shown in Table 2 below.

[0091] Table 1 Schematic diagram of loading force required under standard working conditions

[0092]

[0093] Table 2 Schematic diagram of loading force required for special working conditions

[0094]

[0095] Furthermore, in one embodiment, when both the stress deformation displacement and the residual deformation value are greater than a maximum threshold or less than a minimum threshold, the structural design of the charging port area is updated, specifically including the following steps:

[0096] When the stress deformation displacement and residual deformation values are both greater than the maximum threshold, the structural design standards of the charging port area are improved.

[0097] When the stress deformation displacement and residual deformation values are both less than the minimum threshold, the structural design standards of the charging port area are lowered.

[0098] In this embodiment, if the simulated / physical test results for the vehicle body structure's stress, deformation, displacement, and residual deformation exceed the required values, indicating a significant risk, the vehicle body structure design in that area is improved to eliminate the issue. If the simulated / physical test results for the vehicle body structure's stress, deformation, displacement, and residual deformation are significantly lower than the required values, the vehicle body structure design in that area is optimized to avoid excess performance.

[0099] In a second aspect, an embodiment of the present application also provides an electric vehicle charging port area design system.

[0100] In one embodiment, referring to Figure 3 , Figure 3 This is a functional module diagram of an embodiment of the electric vehicle charging port area design system of this application. Figure 3 As shown, the electric vehicle charging port area design system includes:

[0101] The structure selection module 1 is used to select the body-in-white structure unit corresponding to the charging port area, and set a rigid structure at the position corresponding to the charging port on the body-in-white structure unit.

[0102] Mechanical testing module 2 is used to obtain the loading force when the charging gun is plugged into or unplugged from the charging port, apply the loading force to the rigid structure, and record the force deformation displacement between the rigid structure and the body-in-white structural unit, as well as the residual deformation value of the body-in-white structural unit.

[0103] The design analysis module 3 is used to update the structural design of the charging port area when the stress deformation displacement and the residual deformation values are both greater than the maximum threshold or less than the minimum threshold.

[0104] In this embodiment, a rigid structure is used to simulate the charging port, and a body-in-white structural unit is used to simulate the charging port area. By applying a loading force to the rigid structure, the plugging and unplugging of the charging gun on the charging port is simulated. By calculating the force deformation displacement and residual deformation values between the rigid structure and the body-in-white structural unit, the relative displacement and plastic deformation of the charging port area are analyzed, and the rationality of the current structural design is analyzed, thereby providing a scientific basis and analysis for the structural design of the charging port area.

[0105] This invention proposes performance requirements for the vehicle body in the charging port area of electric vehicles, filling a gap in this area. It also develops a design verification method that allows for efficient and rapid performance verification of the vehicle body in this area. This performance requirement and design verification method are applicable to the design and development of all relevant areas of the vehicle body in electric vehicles. They can quantitatively verify the rationality of the performance design targets for the vehicle body in this area, providing guidance for optimizing the vehicle body structure design in this area and effectively reducing design and development costs as well as after-sales maintenance costs.

[0106] Furthermore, in one embodiment, the method includes:

[0107] The body-in-white structural unit and rigid structure are obtained using modeling methods.

[0108] Finite element analysis is used to apply loading force to the rigid structure to determine whether the structural design of the charging port area should be updated.

[0109] In this embodiment, the finite element method is used to perform static analysis on the body-in-white structural unit in the charging port area. The software used is NASTRAN to simulate the loading force of the charging gun in various postures, that is, the loading force, and calculate the stress deformation displacement and residual deformation value of the body structure.

[0110] Furthermore, in one embodiment, the method includes:

[0111] During modeling, multiple welding points are set on the body-in-white structural unit, and the thickness and properties of the multi-layer materials constituting the body-in-white structural unit, as well as the amount and specifications of the glue coating, are set according to preset standard structural data.

[0112] When conducting finite element analysis, the constraints of the body-in-white structural unit simulate the constraints under the trolley test state, constraining 6 degrees of freedom for the front suspension support of the body-in-white and 6 degrees of freedom for the fixed points of the rear suspension of the body-in-white.

[0113] In this embodiment, when simulating the loading force of the charging gun in various postures and calculating the displacement and residual deformation values under vehicle body structure deformation, the main considerations are as follows:

[0114] The location of weld points in the body-in-white modeling, especially the thickness and properties of multi-layer materials, as well as the amount and specifications of glue.

[0115] The white body constraint simulates the constraint mode under the trolley test state. The front suspension support of the white body constrains 6 degrees of freedom, and the rear suspension fixed point constrains 6 degrees of freedom.

[0116] The charging port is replaced by a rigid unit, and the force acting as a simulated charging gun is loaded on the rigid unit.

[0117] Furthermore, in one embodiment, the method includes:

[0118] The body-in-white structural member is used as the body-in-white structural unit, a charging port bracket is provided on the body-in-white structural member, an aluminum plate is connected to the charging port bracket as a rigid structure, and a rigid tooling is used to fix the body-in-white structural member at the work station.

[0119] When applying the loading force, the loading head of the loading device is used to apply the loading force on the aluminum plate to determine whether the structural design of the charging port area is updated.

[0120] In this example, a representative and mature painted vehicle body was selected and secured with rigid fixtures. A rigid unit simulating a charging port was mounted on the charging port bracket on the vehicle body. Appropriate force-applying equipment was used to load the rigid unit, and the displacement and residual deformation of the vehicle body structure were measured.

[0121] When verifying the body stiffness, the main considerations are as follows:

[0122] ① Select a paint car body that is representative and mature (such as the parts / weld points / glue data and quantity have been solidified, and the car body size / weld points / glue inspection meets the requirements).

[0123] Use rigid tooling to fix the front and rear overhang mounting points of the body in white. The body should not move before and after the loading force is applied (a dial indicator can be installed at a designated position on the body in white, and ensure that the dial indicator is zero before and after each measurement).

[0124] Select an aluminum plate with appropriate thickness (generally >5mm) as the rigid unit of the charging port. The size of the aluminum plate is determined according to the shape of the charging port bracket. Use the charging port fixing holes to fix the aluminum plate to the charging port bracket with bolts.

[0125] Mark the vehicle body displacement measurement point in the charging port area.

[0126] Select appropriate force loading equipment + loading head to load the force, and load each working condition 5 times.

[0127] Use equipment that can measure displacement in three directions of X / Y / Z to measure the displacement measurement points of the vehicle body.

[0128] The verification is carried out on two vehicle bodies: vehicle body 1 undergoes standard working condition test verification, and vehicle body 2 undergoes special working condition test verification.

[0129] Furthermore, in one embodiment, referring to Figure 3 , Figure 3 This is a schematic diagram of the loading force in an embodiment of the electric vehicle charging port area design method of the present application. The method further includes:

[0130] When applying loading force to the rigid structure, multiple and multi-angle applications are adopted to obtain multiple sets of force deformation displacement and residual deformation values. Based on the multiple sets of force deformation displacement and residual deformation values, it is determined whether the structural design of the charging port area should be updated.

[0131] In this embodiment, the loading force is offset at a certain angle within the design allowable range: the loading angle direction of the charging gun is simulated, and the extreme offset angle is formulated according to human-machine operation and the opening range of the charging port shell.

[0132] Furthermore, in one embodiment, the method further includes:

[0133] When applying a loading force to a rigid structure, the loading force is applied to the center point of the rigid structure.

[0134] In this embodiment, the center of the rigid structure corresponds to the center of the outer end surface of the charging port, and the loading direction can be customized.

[0135] Furthermore, in one embodiment, the method further includes:

[0136] When applying loading force to a rigid structure to calculate the load deformation displacement and residual deformation value, select one of the standard working conditions or special working conditions.

[0137] When selecting the standard working condition, the loading force is obtained based on the insertion force, extraction force, and gravity of the charging gun on the corresponding vehicle model.

[0138] When selecting special working conditions, the loading force is obtained according to the design value of the connection strength of the charging gun and the charging port on the corresponding vehicle model.

[0139] In this embodiment, by organizing research activities, information on the charging gun usage habits of electric vehicle users is obtained, and it is organized and analyzed using scientific and objective methods. The stress conditions of the vehicle body in the charging port area are divided into two working conditions: standard working conditions and special working conditions, and loading force requirements are set for these two working conditions respectively.

[0140] Under standard working conditions, the design requirements for the insertion and extraction force of the charging gun of a specific vehicle model and the gravity of the charging device (weight of the charging gun + charging cable) are used as the loading force.

[0141] Under special working conditions, the design value of the connection strength between the charging gun and the charging port of the specific vehicle model is used as the loading force.

[0142] Both working conditions consider the situation where the loading force is offset at a certain angle within the design allowable range, simulate the loading angle direction of the charging gun, and formulate the extreme offset angle according to human-machine operation and the opening range of the charging port shell.

[0143] To meet the functional requirements of electric vehicle charging, the basic requirements for the body stiffness performance in the charging area are that the body area cannot experience large relative displacement during loading of the charging port area, and after unloading, the body area cannot experience obvious plastic deformation.

[0144] Furthermore, in one embodiment, the method further includes:

[0145] When applying the gravity of the charging gun to the rigid structure, the gravity of the charging gun is applied to a preset distance below the center point of the rigid structure.

[0146] Among them, the functional implementation of each module in the above-mentioned electric vehicle charging port area design system corresponds to the various steps in the above-mentioned electric vehicle charging port area design method embodiment, and its functions and implementation processes will not be repeated here one by one.

[0147] Furthermore, in one embodiment, when both the stress deformation displacement and the residual deformation value are greater than a maximum threshold or less than a minimum threshold, the structural design of the charging port area is updated, specifically including the following steps:

[0148] When the stress deformation displacement and residual deformation values are both greater than the maximum threshold, the structural design standards of the charging port area are improved.

[0149] When the stress deformation displacement and residual deformation values are both less than the minimum threshold, the structural design standards of the charging port area are lowered.

[0150] In this embodiment, if the simulated / physical test results for the vehicle body structure's stress, deformation, displacement, and residual deformation exceed the required values, indicating a significant risk, the vehicle body structure design in that area is improved to eliminate the issue. If the simulated / physical test results for the vehicle body structure's stress, deformation, displacement, and residual deformation are significantly lower than the required values, the vehicle body structure design in that area is optimized to avoid excess performance.

[0151] In a third aspect, an embodiment of the present application provides an electric vehicle charging port area design device, which may be a personal computer (PC), a laptop computer, a server, or other device with data processing capabilities.

[0152] In an embodiment of the present application, an electric vehicle charging port area design device may include a processor, a memory, a communication interface, and a communication bus.

[0153] The communication bus may be of any type and is used to interconnect the processor, memory, and communication interface.

[0154] Communication interfaces include input / output (I / O) interfaces, physical interfaces, and logical interfaces, which are used to interconnect components within the EV charging port area design device, as well as interfaces used to interconnect the EV charging port area design device with other devices (such as other computing devices or user devices). Physical interfaces can be Ethernet interfaces, fiber optic interfaces, ATM interfaces, etc. User devices can be displays, keyboards, etc.

[0155] The memory can be various types of storage media, such as random access memory (RAM), read-only memory (ROM), non-volatile RAM (NVRAM), flash memory, optical storage, hard disk, programmable ROM (PROM), erasable PROM (EPROM), electrically erasable PROM (EEPROM), etc.

[0156] The processor may be a general-purpose processor that can call an electric vehicle charging port area design program stored in a memory and execute the electric vehicle charging port area design method provided in the embodiments of the present application. For example, the general-purpose processor may be a central processing unit (CPU). The method executed when the electric vehicle charging port area design program is called can refer to the various embodiments of the electric vehicle charging port area design method of the present application and will not be repeated here.

[0157] In a fourth aspect, an embodiment of the present application also provides a computer-readable storage medium.

[0158] The computer-readable storage medium of the present application stores an electric vehicle charging port area design program, wherein when the electric vehicle charging port area design program is executed by a processor, the steps of the electric vehicle charging port area design method as described above are implemented.

[0159] Among them, the method implemented when the electric vehicle charging port area design program is executed can refer to the various embodiments of the electric vehicle charging port area design method of this application, and will not be repeated here.

[0160] It should be noted that the serial numbers of the above-mentioned embodiments of the present application are for description only and do not represent the advantages or disadvantages of the embodiments.

[0161] The terms "including" and "having" and any variations thereof in the specification and claims of this application and the above-mentioned drawings are intended to cover non-exclusive inclusions. For example, a process, method, system, product or device that includes a series of steps or units is not limited to the listed steps or units, but optionally includes steps or units that are not listed, or optionally includes other steps or units inherent to these processes, methods, products or devices. The terms "first", "second" and "third" are used to distinguish different objects, etc., and do not represent a sequence, nor do they limit the "first", "second" and "third" to different types.

[0162] In the description of the embodiments of this application, the words "exemplary," "for example," or "for example" are used to indicate examples, illustrations, or descriptions. Any embodiment or design described as "exemplary," "for example," or "for example" in the embodiments of this application should not be construed as being preferred or advantageous over other embodiments or designs. Rather, the use of words such as "exemplary," "for example," or "for example" is intended to present the relevant concepts in a concrete manner.

[0163] In the description of the embodiments of the present application, unless otherwise specified, “ / ” means or, for example, A / B can mean A or B; “and / or” in the text is merely a description of the association relationship of associated objects, indicating that three relationships may exist, for example, A and / or B can mean: A exists alone, A and B exist at the same time, and B exists alone. In addition, in the description of the embodiments of the present application, “multiple” refers to two or more than two.

[0164] In some processes described in the embodiments of the present application, multiple operations or steps are included that appear in a specific order. However, it should be understood that these operations or steps may not be performed in the order in which they appear in the embodiments of the present application or may be performed in parallel. The sequence numbers of the operations are only used to distinguish between different operations, and the sequence numbers themselves do not represent any order of execution. In addition, these processes may include more or fewer operations, and these operations or steps may be performed in sequence or in parallel, and these operations or steps may be combined.

[0165] Through the description of the above implementation methods, those skilled in the art can clearly understand that the above-mentioned embodiment methods can be implemented by means of software plus the necessary general hardware platform, of course, it can also be implemented by hardware, but in many cases the former is a better implementation method. Based on this understanding, the technical solution of the present application, or the part that contributes to the prior art, can be embodied in the form of a software product, which is stored in a storage medium (such as ROM / RAM, magnetic disk, optical disk) as described above, and includes a number of instructions for enabling a terminal device to execute the methods described in each embodiment of the present application.

[0166] The above are only preferred embodiments of the present application and do not limit the patent scope of the present application. Any equivalent structure or equivalent process transformation made using the contents of the present application specification and drawings, or directly or indirectly applied in other related technical fields, are also included in the patent protection scope of the present application.

Claims

1. A method for designing an electric vehicle charging port area, characterized in that: The electric vehicle charging port area design method includes: Select the body-in-white structural unit corresponding to the charging port area, and set a rigid structure at the position corresponding to the charging port on the body-in-white structural unit; Obtain the loading force when the charging gun is plugged into or unplugged from the charging port, apply the loading force to the rigid structure, and record the force-deformation displacement between the rigid structure and the body-in-white structural unit, as well as the residual deformation value of the body-in-white structural unit; When the stress deformation displacement and the residual deformation values are both greater than the maximum threshold or less than the minimum threshold, the structural design of the charging port area is updated.

2. The electric vehicle charging port area design method according to claim 1, characterized in that: The method comprises: Obtaining the body-in-white structural unit and the rigid structure by using a modeling method; Finite element analysis is used to apply the loading force to the rigid structure to determine whether the structural design of the charging port area should be updated.

3. The electric vehicle charging port area design method according to claim 2, characterized in that: The method comprises: During modeling, multiple welding points are set on the body-in-white structural unit, and the thickness and properties of the multi-layer materials constituting the body-in-white structural unit, as well as the amount and specifications of the glue coating, are set according to the preset standard structural data; When conducting finite element analysis, the constraints of the body-in-white structural unit simulate the constraints under the trolley test state, constraining 6 degrees of freedom for the front suspension support of the body-in-white and 6 degrees of freedom for the fixed points of the rear suspension of the body-in-white.

4. The electric vehicle charging port area design method according to claim 1, characterized in that: The method comprises: The body-in-white structural member is used as the body-in-white structural unit. A charging port bracket is provided on the body-in-white structural member. An aluminum plate is connected to the charging port bracket as a rigid structure. Rigid tooling is used to fix the body-in-white structural member in the work station. When applying the loading force, the loading head of the loading device is used to apply the loading force on the aluminum plate to determine whether the structural design of the charging port area is updated.

5. The electric vehicle charging port area design method according to claim 1, characterized in that: The method further comprises: When applying the loading force to the rigid structure, multiple and multi-angle applications are adopted to obtain multiple sets of force deformation displacements and residual deformation values, and it is determined whether the structural design of the charging port area should be updated based on the multiple sets of force deformation displacements and residual deformation values.

6. The electric vehicle charging port area design method according to claim 1, characterized in that: The method further comprises: When applying a loading force to a rigid structure, the loading force is applied to the center point of the rigid structure.

7. The electric vehicle charging port area design method according to claim 1, characterized in that: The method further comprises: When applying loading force to a rigid structure to calculate the load deformation displacement and residual deformation value, select one of the standard working conditions or special working conditions; When the standard working condition is selected, the loading force is obtained based on the insertion force and extraction force of the charging gun on the corresponding vehicle model, as well as the gravity of the charging gun; When a special operating condition is selected, the loading force is obtained based on the design value of the connection strength between the charging gun and the charging port on the corresponding vehicle model.

8. The electric vehicle charging port area design method according to claim 7, characterized in that: The method further comprises: When applying the gravity of the charging gun to the rigid structure, the gravity of the charging gun is applied to a preset distance below the center point of the rigid structure.

9. The electric vehicle charging port area design method according to claim 1, characterized in that: When the stress deformation displacement and the residual deformation values are both greater than the maximum threshold or less than the minimum threshold, updating the structural design of the charging port area specifically includes the following steps: When both the stress deformation displacement and residual deformation values are greater than the maximum threshold, the structural design standards of the charging port area are improved; When the stress deformation displacement and residual deformation values are both less than the minimum threshold, the structural design standards of the charging port area are lowered.

10. An electric vehicle charging port area design system, characterized in that: The electric vehicle charging port area design system includes: A structure selection module, which is used to select a body-in-white structural unit corresponding to the charging port area and set a rigid structure at the position corresponding to the charging port on the body-in-white structural unit; The mechanical testing module is used to obtain the loading force when the charging gun is plugged into or unplugged from the charging port. The loading force is applied to the rigid structure, and the force-induced deformation displacement between the rigid structure and the body-in-white structural unit, as well as the residual deformation value of the body-in-white structural unit, is recorded. The design analysis module is used to update the structural design of the charging port area when the stress deformation displacement and residual deformation values are both greater than a maximum threshold or less than a minimum threshold.

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