ALIVE, ENLIGHT & epsilon Final Workshop · ALIVE, ENLIGHT & epsilon Final Workshop ... Structural...

© epsilon consortium 2016

Funded by

the Seventh Framework Programme

of the European Union

Johannes Stein / Final Event 1

ALIVE, ENLIGHT & epsilon Final Workshop

epsilon – Structural Design of Body and Battery Housing

Aachen, 22 September 2016

Dipl.-Ing. Johannes Stein

Institute for Automotive Engineering


Funded by




Agenda

Package Investigation

Structural BIW Concept

Vehicle Safety Investigation

Summary and Outlook


Funded by





Vehicle Type

Segment M0, Sub-A

Seats 2 (M95th) +1 (F5th)

Units per year 50,000

SOP 2020

Technical Specs and Targets

Curb weight 600 kg

Gross vehicle weight 850 kg

Battery 15.6 kWh (Kreisel)

Cd x A 0.25 x 1.8 m²

Range (urban) > 150 km

Max. velocity 120 km/h

Acceleration (1-100 km/h) < 10 s

Electric motor 80 kW (Bosch)

Gearbox ratio 1:9.59 (GKN)

Front axle McPherson

Rear axle rigid axle

Front tires 145/65 R15

Rear tires 175/55 R15

Turning circle < 9 m

NCAP rating 4 stars

Exterior Dimensions

Interior Dimensions

Length 3100 mm

Width 1500 mm

Height 1460 mm

Wheelbase 2040 mm

Front track 1295 mm

Rear track 1257 mm

Headroom driver 980 mm

Headroom co-driver 980 mm

Headroom 2nd row 850 mm

Shoulder room front 1190 mm

Shoulder room rear 1080 mm

Trunk volume 100 – 260 l

Functional Objectives

Car sharing capability

Mainly for urban commuting

Modularity for families

Easy to use

Agile in urban environment

Re

fere

nc

es

Smart Fortwo E Renault Twizy Tazzari Zero L: 2695 mm

W: 1559 mm

H: 1565 mm

L: 2335 mm

W: 1228 mm

H: 1454 mm

L: 2880 mm

W: 1560 mm

H: 1425 mm


Funded by





Package concept Drivetrain concept

Chassis concept

BiW concept

Vehicle concept

Cooler Inverter; DC/DC Motor

HV Battery Charger

Transmission

MC Pherson

Omega beam


Funded by




Radiator

and fan

Inverter/

Converter

E-motor

HV-Battery

AC-charger

HVAC-box

Transmission

12V-battery

McPherson axle

Hybrid CFRP-metal rear axle

PTC heater



Funded by




Agenda




Summary and Outlook


Funded by




0

200

400

600

800

1000

1200

1400

1600

1800

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Mas

s [k

g]

Volume [m³]

Renault Twizy

epsilon

Smart Fortwo E

Mitsubishi iMiEV

VW e-up

BMW i3

VW e-Golf

Nissan Leaf

Need for lightweight design

to achieve epsilon target

Renault Twizy Smart Fortwo E epsilon Mitsubishi iMiEV VW e-up BMW i3 VW e-Golf Nissan Leaf

Lenght [m] 2,335 2,695 3,100 3,475 3,540 3,999 4,270 4,445

Width [m] 1,228 1,559 1,500 1,475 1,641 1,775 1,799 1,770

Height [m] 1,454 1,565 1,460 1,610 1,489 1,578 1,450 1,545

Volume [m³] 4,169 6,575 6,789 8,252 8,650 11,201 11,139 12,156

Weight [kg] 506 900 600 1099 1139 1381 1538 1534

[kg/m³] 121 137 88 133 132 123 138 126



Funded by





Geometrical lightweight design Conceptual lightweight design Material lightweight design

Half monocoque with front and rear end

Monocoque on frame

Full monocoque

Steel

Aluminium

Magnesium

Thermoplastic

Lightweight design by

topology optimisation

CAD Model

Topology optimisation

Lightweight body

[FRI13] [NN16]

Holistic lightweight design approach


Funded by





The methodological approach is to identify optimum

load paths in the given BIW design space:

Euro NCAP-crash front, side, pole, rear

Static bending

Static torsion

Based on the topology optimisation, the following

design requirements for the BIW can be derived:

Continuous A-pillar to roof pillar

Increased sill for battery protection

Continuous B-pillar to roof cross member

Lower B-pillar cross member

High strength greenhouse

Geometrical lightweight design by topology optimisation Package concept Design concept

BIW design space

Finite element model

Topology optimisation BIW

BIW lightweight structure


Funded by




CFRP-Al-Space-Frame

Structurally integrated rear seat Maximising BIW stiffness

Structurally integrated battery


Conceptual lightweight design


Funded by




-A mixed-material solution, based on CFRP and aluminium - Aluminium front, rear and side deformation zones

-Non-structural injection moulded outer panels - CRFP space frame passenger compartment

CFRP-Al-Space-Frame Tailored shear panels GFRP exterior panels

Material lightweight design

CFRP beam

Foam core



Funded by




Weight target full vehicle: 600 kg Weight target body: 210 kg

Current weight: 211 kg

210 kg 35 %

168 kg 28 %

96 kg 16 %

60 kg 10 %

66 kg 11 %

Body

Drive Train

Chassis

Electronics

Interior


112 kg 53 %

35 kg 16 %

35 kg 17 %

21 kg 10 %

8 kg 4 %

BIW

Doors and closures

Exterior

Glazing

Hang-on parts/brackets


Funded by




Agenda




Summary and Outlook


Funded by




Translation locked

in Y, Z

Translation locked

in X, Y, Z

Translation locked

in Z

Translation locked

in X, Z

x

z

y

z

y x

mm

kNcBending 313.19

kNcTorsion 175.31

Bending Stiffness Torsion Stiffness

Lightweight quality index: 𝐿𝑇 =mBIW

cT ∙AT= 1.38



Funded by




Vehicle Safety Investigation 1 2 3

4 5 6

# Crash Test

1 Euro NCAP full width rigid barrier front crash

2 Euro NCAP offset deformable barrier front crash

3 Euro NCAP moveable deformable barrier side crash

4 Euro NCAP side pole crash

5 FMVSS 216 roof test

6 FMVSS 301 offset deformable barrier rear crash


Funded by





Euro NCAP full width rigid barrier front crash

video

AKT_VIDEOS_NEW/FW_SLOW.avi


Funded by





Euro NCAP offset deformable barrier front crash

video

AKT_VIDEOS_NEW/ODB_SLOW.avi


Funded by




Euro NCAP moveable deformable barrier side crash


video

AKT_VIDEOS_NEW/SIDE_SLOW.avi


Funded by




Euro NCAP side pole crash


video

AKT_VIDEOS_NEW/POLE_SLOW.avi


Funded by




FMVSS 216 roof test


video

AKT_VIDEOS_NEW/216_SLOW.avi


Funded by




FMVSS 301 offset deformable barrier rear crash


video

AKT_VIDEOS_NEW/301_SLOW.avi


Funded by





Front structure is mounted to the crash wall via 5 load cells

„Wishbone“ dummy included

Weight of trolley with wooden plate: 997kg

Test speed: 30kph

Testing: reduced front structure - full width rigid barrier


Funded by





High speed video: reduced front structure - full width rigid barrier

video

AKT_VIDEOS_NEW/VORDERWAGEN_VERGLEICH.avi


Funded by





0.01 0.02 0.07 0.080.03 0.060.04 0.050.00

0

20

40

60

80

Fo

rce

Fx

[kN

]

Time t [s]

0.01 0.02 0.07 0.080.03 0.060.04 0.050.00

0

20

40

60

80

Fo

rce

Fx

[kN

]

Time t [s]

Measurement Data FEM Simulation Data


Funded by




Agenda




Summary and Outlook


Funded by




Structural Design

- Novel CFRP-Al-Space-Frame body architecture

- Vehicle safety investigation for several different loadcases

- Testing of reduced front structure

Outlook

-Testing: Focus on the core development targets in vehicle safety, energy efficiency and vehicle dynamics

-Vehicle safety will be tested in the Euro NCAP full width rigid barrier front crash

Summary and Outlook


Funded by




Summary and Outlook

Prototyping


Funded by




Summary and Outlook


Funded by




Thank you for your attention!

Funded by




Funded by




Contact

Dipl.-Ing. Johannes Stein

Institute for Automotive Engineering (ika)

RWTH Aachen University

Steinbachstr. 7

52074 Aachen

Germany

Phone +49 241 80 25 701

Fax +49 241 80 22147

E-mail [email protected]

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