Topology Optimization of Electric Motor Installation

Abstract

Early design of a large component which is subjected to a wide range of complex loads, from loads caused by extreme driving conditions to crash loads, is no easy task. In the highly competitive automotive industry, reducing weight while retaining performance is a big priority. This thesis has investigated topology optimization as a tool to aid early design for an electric engine installation. Topology optimization has the potential to produce a well defined topology while simultaneously consider several load cases, design constraints and behavioural constraints. The load cases investigated in this thesis are engine loads, road induced loads and crash loads. The crash loads have a non-linear and transient behaviour and it has been investigated whether they can be applied as linear and static loads in an early design phase. A superelement has been used to reduce computational time while still capturing the behaviour from the body in white. As the loads vary greatly in magnitude, different constraints on different load cases have been investigated. Through a display of different trial cases a methodology has been produced. Although more validation is desirable, the results are promising, robust and efficiently generated. As well as showing where material is needed, topology optimization can also indicate where material is not needed.