The development of Electric Vehicle is not only a replacement of power source, but a new process of reasonable design and development on the mechanical structure and power system. Considering the strained condition of the support structure when the Electric Vehicle is under the four typical working conditions: accelerating, braking, steering and vertical impact, the dynamic design method and finite element theory are adapted to analysis its strength and mode, while the orthogonal test method is used to analyze the influencing factors of its modes. Combining the size optimization, the weight of the power system's support structure has been reduced. This method, which has been adapted in the independent development of an Electric Vehicle, will provide a useful reference for the dynamical and lightweight design of similar mechanical structure.
