Static load simulation analysis on chassis of electric mini bus integrated with the support frame of removable battery pack by using FEA

Abstract

Design analysis of chassis especially electric mass transportation was very crucial due to the addition of battery pack weight about a half of total vehicle weight. This present study aims to redesign, simulate and perform the stress analysis of the structural mini bus chassis by using Finite Element Analysis (FEA). The main chassis was reinforced by the battery support structure frame of the removable battery pack to achieve optimal safety factor at maximum total load. Maximum loads were varied, they were 3.6, 4, 4.5, and 5 ton. The material also varied, ASTM A302 and ASTM A710. It found that high stress and maximum deflection area locations in chassis were identified as weakness area, and it needs to recover by the addition of the battery support structure frame. The best structure frame is the lightest structure with the highest safety factor and achieved above 1 level of safety factor. Also, the maximum deflection was tolerated. The result of FEA simulation was showed that the selected design of support frame was the best design for electric mini bus and it became reference for future design.