Automotive Workshop on BiW-Structures - ENLIGHT - …€¦ ·  · 2014-08-19Automotive Workshop on...

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© SEAM 2012 Slide No. 1 Bein / Mondragon Automotive Workshop Automotive Workshop on BiW-Structures Body Engineering Trends – The FP7 SEAM Cluster Mondragon, 11 July 2013 Thilo Bein Fraunhofer LBF

Transcript of Automotive Workshop on BiW-Structures - ENLIGHT - …€¦ ·  · 2014-08-19Automotive Workshop on...

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© SEAM 2012 Slide No. 1Bein / Mondragon Automotive Workshop

Automotive Workshop on BiW-Structures

Body Engineering Trends – The FP7 SEAM Cluster

Mondragon, 11 July 2013

Thilo BeinFraunhofer LBF

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© SEAM 2012 Slide No. 2Bein / Mondragon Automotive Workshop

Outline

Preface

Lightweight design for mobility

The SEAM cluster

Future mobility

Summary

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© SEAM 2012 Slide No. 3Bein / Mondragon Automotive Workshop

Preface

In the year 2050 more than 9 bn. humans will live on earth. (UN)

In the next 30 years 450 mill. Chinese people will live in cities, which are not existing, yet. (Lutz Engelke, Trias Projektgesellschaft mbH, auto motor sport-Kongress 2010)

Up to the year 2030 appr. 500 cities will exist with a population over amillion citizens. 27 of them will be megacities.

(8th world congress of network Metropolis - World Ass. of Major Metropolises)

Increasing demand on urban mobility

[www.wienweb.at]www.cai.blogware.com

… with zero-emission ideally

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© SEAM 2012 Slide No. 4Bein / Mondragon Automotive Workshop

Outline

Preface

Lightweight design for mobility

The SEAM cluster

Future mobility

Summary

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© SEAM 2012 Slide No. 5Bein / Mondragon Automotive Workshop

Challenges for Future Mobility

[Source: Grotendorst, Continental, 2009]

Limited FuelPrice / availability of oil Increasing traffic (passenger and transport)

Reduced emissions CO2 Emissions DevelopmentC02 emission development

160 130 95 70

2006 2012 2020 2025

www.in-brasilien.de

in g CO2/km

Bild: AP

Until 2030 in the transport sector, the predicted increase of fuel demand totals 55 %

US Tier2Bin5

EU 5 Sept-2009

Phase IIJan-2010

NationalJan-2010

Phase IIIJan-2013

EU6Sept-2014

PMNOX

CO

HC§

Exh

aust

gas

em

issi

on

s

We have to reduce weight of all kind of vehicles

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© SEAM 2012 Slide No. 6Bein / Mondragon Automotive Workshop

Life cycle fuel efficiency improvement by lightweight

200,000 km

1,000,000 km

4,000,000 km

Data from: Helms, LCA case studies – 2006 Vehicle []

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© SEAM 2012 Slide No. 7Bein / Mondragon Automotive Workshop

Global fuel savings by lightweighting

Data from: Helms, LCA case studies – 2006

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© SEAM 2012 Slide No. 8Bein / Mondragon Automotive Workshop

Contribution of vehicle systems to total weight

Body & chassis/suspension components are loaded by fluctuating forces

Significant improvement on material & mass efficiency can be generated only by managing the stress vs. strength interference

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© SEAM 2012 Slide No. 9Bein / Mondragon Automotive Workshop

Challenges and strategies of lightweight design

Source: M.Goede, VW Group Research

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© SEAM 2012 Slide No. 10Bein / Mondragon Automotive Workshop

Material mix/technology to lower vehicle weight

Steel intensive vehiclestructure is cost effective

Aluminum and compositesbecome more often used

Vehicle life cycle and end-of-life-vehicle have to beconsidered

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© SEAM 2012 Slide No. 11Bein / Mondragon Automotive Workshop

Trend towards multi-material design

Source: M.Goede, VW Group Research, SLC

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© SEAM 2012 Slide No. 12Bein / Mondragon Automotive Workshop

But … GHG emission must be considered of complete life-time

Source: M.Goede, S. Krinke, VW Group Research

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© SEAM 2012 Slide No. 13Bein / Mondragon Automotive Workshop

CO2-profiles in the production phase

Source: M.Goede, S. Krinke, VW Group Research

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© SEAM 2012 Slide No. 14Bein / Mondragon Automotive Workshop

Lightweight design throughout the life-cycle

Source: M.Goede, S. Krinke, VW Group Research

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© SEAM 2012 Slide No. 15Bein / Mondragon Automotive Workshop

Additional manufacturing costs

Source: Fine, Roth, MIT MSL, MIT Manufacturing Round Table, 2010

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© SEAM 2012 Slide No. 16Bein / Mondragon Automotive Workshop

Weight saving considering secondary savings

Source: Fine, Roth, MIT MSL, MIT Manufacturing Round Table, 2010

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© SEAM 2012 Slide No. 17Bein / Mondragon Automotive Workshop

Outline

Preface

Lightweight design for mobility

The SEAM cluster

Future mobility

Summary

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© SEAM 2012 Slide No. 18Bein / Mondragon Automotive Workshop

Lightweight as development target

-10%

Mass reduction: > 250 kg

Base data: Affenzeller, AVL Vehicle mass [kg]

to meet the CO2 targets of ICE-driven cars(-100 kg = 8.5 gCO2/km)

to compensate for themass of the battery

to reduce the mass ofthe battery

to extend the range ofHEV/FEV

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© SEAM 2012 Slide No. 19Bein / Mondragon Automotive Workshop

Main Challenges: Driving Range and Battery Costs

25-

20-

15-

10-

5-

0-

[Data: Corsini, GM Europe, 2009]

Besides battery technologies, light weight is the key

0-1 2-4 5-10 11-20 21-50 51-100 >100

% o

f cu

stom

ers

km

80 % of all customers driveless than 50 km per day

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© SEAM 2012 Slide No. 20Bein / Mondragon Automotive Workshop

Mass vs. energy for zero-emission vehicles

10 kWh

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© SEAM 2012 Slide No. 21Bein / Mondragon Automotive Workshop

ApproachTwo different proposals were initiated , each addressing the complete vehicle (BiW, hang-on parts, chassis (suspension) and interior) but ALIVE addressing matured technologies focusing on their deployment

in vehicle structures, ENLIGHT addressing highly innovative materials. Differentiation is done by type of materials considered

both projects are based on vehicle architecture currently being considered in ELVA and e-LIGHT

target vehicle is a 2-4 passenger car for mass production weight reduction will be assessed against energy and CO2-reduction ALIVE will be the benchmark for solutions developed in ENLIGHT

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© SEAM 2012 Slide No. 22Bein / Mondragon Automotive Workshop

Correlation between ALIVE and ENLIGHT

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© SEAM 2012 Slide No. 23Bein / Mondragon Automotive Workshop

ENLIGHT/ALIVE display production volume correlation

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© SEAM 2012 Slide No. 24Bein / Mondragon Automotive Workshop

Modeling and testing for improved safety of key composite structures in alternatively powered vehicles

Safe small electric vehicles through advanced simulation methodologies

Coordinator: fka Coordinator: ViF

Coordinator: Fraunhofer LBFCoordinator: VW

Advanced high volume affordable lightweighting for futureelectric vehicles

Enhanced lightweight design byadvanced lightweight materials

Liaison TeamC.R.F, VW, fka,

ViF, LBF, B&W

Biggest European RTD-Cluster on lightweight design

47 partner from 11 countries, about 19 Mio. € funding

joint dissemination activities between the SEAM projects

The two new projects EPSILON & URBAN-EV will joinas associated partners in September 2013

Contact:Prof. Dr.-Ing. Thilo Bein

E-Mail: [email protected]: www.seam-cluster.eu

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© SEAM 2012 Slide No. 25Bein / Mondragon Automotive Workshop

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© SEAM 2012 Slide No. 26Bein / Mondragon Automotive Workshop

All 4 SEAM projects are linked and have ties to several European projects

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© SEAM 2012 Slide No. 27Bein / Mondragon Automotive Workshop

The ALIVE Project - Motivation

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© SEAM 2012 Slide No. 28Bein / Mondragon Automotive Workshop

The ALIVE Project - Objectives

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© SEAM 2012 Slide No. 29Bein / Mondragon Automotive Workshop

The ALIVE Project – Weight Targets

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© SEAM 2012 Slide No. 30Bein / Mondragon Automotive Workshop

The ALIVE Project – Key Deliverables

Design capabilities and innovative structural layouts for affrodable high volume lightweight EV

Materials and manufacturing capabilities for affordable high volume lightweight EV

Experimental and simulation validation environments to allow for quick & reliable multi-parameter design & optimisation loops

Demonstration of the abovementionend results into a full scale demonstrator vehicle covering BiW, hang-on parts, chassis and heavy interiors, including battery pack integration, innovative safety mechanism and several new materials and manufacturing technologies

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© SEAM 2012 Slide No. 31Bein / Mondragon Automotive Workshop

The ENLIGHT Project – Objectives

Development of highly innovative lightweight / low embedded CO2materials for their application in medium-volume automotive production (50.000 units/year)

Design capabilities for affordable medium-volume lightweight EVs Manufacturing and joining capabilities for affordable medium-volume

lightweight EVs Demonstration of the proposed solutions through the realization of at

least 5 full scale demonstrator modules, covering different distinguishing features of purpose-designed EVs: Front module, Firewall, Central floor section, Sub-frame & suspension, and Doors / enclosures

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© SEAM 2012 Slide No. 32Bein / Mondragon Automotive Workshop

The ENLIGHT Project – Weight targets

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© SEAM 2012 Slide No. 33Bein / Mondragon Automotive Workshop

The ENLIGHT Project – Key deliverables each considered module saves 20% weight compared to the

respective component of the ALIVE project Availability and implementation of advanced lightweight materials

such as hybrids, CFRPs or thermoplastics Qualification of renewables and low-cost fibres for the automotive sector

meeting current automotive standards and required manufacturing costs New, advanced materials meet specifications regarding weight savings,

crashworthiness and applicability in medium-scale production (50.000 units/year)

Elaboration of material data and models for new lightweight materials such that they can be implemented in the vehicle design

Elaboration of testing procedures for new materials, components and sub-systems Validated accelerated test methods reducing test time by half Durability of components and sub-systems proven according automotive

standards Crashworthiness of components and sub-systems proven meeting a

EuroNCAP of between 4 and 5 *

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© SEAM 2012 Slide No. 34Bein / Mondragon Automotive Workshop

The MATISSE Project – Objectives

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© SEAM 2012 Slide No. 35Bein / Mondragon Automotive Workshop

The SafeEV Project – Objectives

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© SEAM 2012 Slide No. 36Bein / Mondragon Automotive Workshop

The SEAM cluster facilitates interaction between the 4 projects

Coordinating meetings between projects

Follow up common GANTT chart, deliverables exchanges

Preparing / organising the Liaison Group telcons and meetings

Coordination of common dissemination / exploitation activities

final exhibitions, workshops, conferences, and training courses

Establishing web-pages, email newsletter, and leaflet

Communication of relevant events / information to partners

Providing best practices for exploitation activities and coordinating them

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© SEAM 2012 Slide No. 37Bein / Mondragon Automotive Workshop

Outline

Preface

Lightweight design for mobility

The SEAM cluster

Future mobility

Summary

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© SEAM 2012 Slide No. 38Bein / Mondragon Automotive Workshop

Shaping future mobility

Sustainable vehicletechnology moves toelectric drives

Conversion design provides chance tomarket productsinitially

Performance, weightand costs of batterysystems are an open issue

New vehicle conceptshave to „re-invent“ thestructure of a passenger car

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© SEAM 2012 Slide No. 39Bein / Mondragon Automotive Workshop

Integration of wheel + drive Centralized/de-centralized energy storages Active and passive assistant systems How-to-drive (speed, distance etc.) Where-to-drive (route, traffic jam, parking etc.)

Reduction of resistance Aerodynamics Lightweight structures + optimized tire/wheel systems

Future concepts for zero-emission vehicles

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© SEAM 2012 Slide No. 40Bein / Mondragon Automotive Workshop

New driveline concepts for small urban vehicles

Flexibility with regard to design and package

»Torque vectoring« and all-wheel traction

Co-operative braking

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© SEAM 2012 Slide No. 41Bein / Mondragon Automotive Workshop

Summary

Population and economic growth create a huge demand fortransportation

Energy is »driving« transportation engineering – searching for moresustainable and efficient concepts related to transport & vehicles

Lightweight helps to improve energy efficiency especially for passenger cars and trucks

Materials and manufacturing are enablers to come up with the mostcost efficient and robust lightweight solutions

Lightweight design needs sophisticated methods for data acquisition, dataprocessing, material characterization & fatigue testing, as well asdesign & development