Motor end cover mounting fracture is a problem recently encountered by novel pure electric\nvehicles. Regarding the study of the traditional vehicle engine mount bracket and on the basis of\nthe methods of design and optimisation available, we have analysed and optimised the pure electric\nvehicle end cover mount system. Multi-body dynamic software and finite element software have\nbeen combined. First, we highlight the motor end cover mount bracket fracture engineering problems,\nanalyse the factors that may produce fracture, and propose solutions. By using CATIA software to\nestablish a 3D model of the power train mount system, we imported it into ADAMS multi-body\ndynamic software, conducted 26 condition analysis, obtained five ultimate load conditions, and laid\nthe foundations for subsequent analysis. Next, a mount and shell system was established by the\nANSYS finite element method, and modal, strength, and fatigue analyses were performed on the end\ncover mount. We found that the reason for fracture lies in the intensity of the end cover mount joint,\nwhich leads to the safety factor too small and the fatigue life not being up to standard. The main\ngoal was to increase the strength of the cover mount junction, stiffness, safety coefficient, and fatigue\nlife. With this aim, a topology optimisation was conducted to improve the motor end cover. A 3D\nprototype was designed accordingly. Finally, stiffness, strength, modal, and fatigue were simulated.\nOur simulation results were as follows. The motor end cover suspension stiffness increases by 20%,\nthe modal frequency increases by 2.3%, the quality increases by 3%, the biggest deformation decreases\nby 52%, the maximum stress decreases by 28%, the minimum safety factor increases by 40%, and life\nexpectancy increases 50-fold. The results from sample and vehicle tests highlight that the component\nfracture problem has been successfully solved and the fatigue life dramatically improved.
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