The ENLIGHT Project · Space frame design Modularity in battery and BiW design SuperLIGHT-Car...

© ENLIGHT 2012 Slide No. 1Name / Event

The ENLIGHT Project

Enhanced Lightweight DesignSCP2-GA-2012-314567

Introduction of project rationale, approach and scope


General Information

Project full title: Enhanced Lightweight Design (ENLIGHT)

THEME [GC.NMP.2012-2 GC.NMP.2012-2]

[Innovative advanced lightweight materials for the next generation of environmentally-friendly electric vehicles], Grant Agreement No. 314567

Coordinator: Fraunhofer LBF, Thilo Bein

Start Date of contract: 01/10/2012

Duration: 48 months

Total Budget: 10,9 MEUR

Funding: 7,1 MEUR


Partners

CRF Magneti Marelli Università degli Studi di Firenze

Fraunhofer LBF Volkswagen Benteler ika PE International Tecnaro

D

Renault

F

KU Leuven

B

Bax & Willens Sistemas y Procesos Avanzados

E I

Volvo Oxeon Swerea SICOMP

S

AIT

A

P

IDMEC

DSM Airborne

NL

GB

Jaguar Land Rover University of Warwick


Motivation

-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

…but with same safety and comfort

Lightweight as development target


Motivation - Mass vs. energy for zero-emission vehicles

10 kWh


Motivation - Trend towards multi-material design

Source: M.Goede, VW Group Research, SLC


ConceptELVA

Concept of light BiW for EV´s

Space frame design

Modularity in battery and BiW

design

SuperLIGHT-Car Economic demonstration of

multimaterial vehicle structuresfor high-volume producedcombustion cars

Source: Fraunhofer LBF, „SmartBatt“ project“ Source: „ELVA“ project, 2013

Source: „SuperLIGHT-Car“ project, 2009

SmartBatt

Fully integrated battery housing

Lightweight battery concept

New materials for battery

systems

MATISSE Modeling and testing

Safety of composite structures

SafeEV Modeling and testing of small EVs

Safety of vulnerable road users

ALIVE High volume

Low weight

Low costsSource: M. Kurz , Volkswagen Group Research, K-EFFG/L, 2013

ENLIGHT medium volume

Novel materials

Low weight


Objectives

Development of highly innovative lightweight / low embedded CO2 materials 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

Experimental and simulation validation environments to enable rapid & reliable multi-parameter optimisation loops when designing with these new materials

LCA and economic analysis to ensure the highest probability of application by 2020, taking into account all salient factors

Demonstration of the proposed solutions through the realization of 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


Weight Targets

ModuleBenchmark

EV (Nissan Leaf)

SLC impact ALIVE ENLIGHT

% reduction

over ALIVE

% reduction over SLC

% reduction over

benchmark EV

BiW (medium risk) 380 266 215-230 172-184 -20.0% -33.8% -53.7%

BiW (high risk) 380 266 200 160 -20.0% -39.9% -57.9%

Chassis 270 270 200 160 -20.0% -44.0% -44.0%

Heavy interior 100 100 70 56 -20.0% -40.0% -40.0%

Hang-on parts 100 100 75 60 -20.0% -40.7% -40.7%

Overall (best case) 850 736 545 436 -20.0% -40.8% -48.7%

Overall (worst case) 850 736 575 460 -20.0% -37.5% -45.9%


Work Structure

LCA

&

ELV

front-enddoor-

modulesuspensionsub-frame firewall

material modeling & simulation

manufacturing

validation & demonstration

module design

material development

characterisation & testing

advanced hybrid materials

fibre-reinforced plastics

composites

renewables

centralfloor

vehicle concepts from ELVA


WP 1 Module Design

conceptual design of selected modules

subframe & suspension

front module

firewall & cockpit

doors / enclosures

central floor module

conceptual design of selected modules front module:

increased crash performance subframe & suspension:

function integration and improved NVH door/enclosures:

function, integration, increased crash performance and improved NVH

cockpit & firewall: function integration, improved acoustics

central floor module: function integration, strength and stiffness properties

• the full vehicle is considered in a virtual design approach.

• use of highly advanced materials, fully exploiting their unique properties regarding lightweight potential (specific strength, weight or stiffness), crash and NVH behavior


WP 2 Simulation

Material and vehicle simulation

• Development, calibration and validation ofmaterial models that allow the description ofthe material behaviour in all relevant simulationenvironments

• Validation and calibration of material modelsby mechanical testing

• Simulation and optimisation of attributes on module level


WP 3 Material Development

allow manufacture at medium production volumes

provide affordable vehicle solutions

have added functionality and/or increased safety

Development of novel lightweight materials


WP 4 Manufacturing

Adapted manufacturing technologies for novel lightweight materials

welded stiffeners

• development and the technological feasibility evaluation of innovative

manufacturing, welding and assembly technologies

for the multi-material concepts/modules

• resulting in a smaller number of parts within the overall vehicle architecture

• Consideration of a production volume of about 50.000 modules per year.


WP 5 Characterisation & Testing

Testing on component and module level

• Provision of experimental data for validation of the module design and numerical models.

• Development of a characterisation and testing strategy considering accelerated testing

• These strategies will then be applied on component level and module level


WP 6 Validation / Proof of Feasibility

• realization of the modules in hardware applying the developed ENLIGHT materials and manufacturing technologies

• proving the feasibility of applying highly advanced lightweight materials as well as the corresponding manufacturing technologies in medium volume production

• validation on module level, the realized weight saving and performance with respect to static and dynamic behavior, structural durability and NVH

• validation of the full vehicle virtual design

Validation of weight targets and manufacturing concepts


WP 7 LCA

Life-cycle analysis and life-cycle cost assessment

• Assessment and comparison of the CO2 emissions and the mass/energy balance related to the whole life cycle of the modules

• Defining of the vehicle recyclability/recoverability

• Analysis of the advantages/drawbacks of a substitution of metallic with non-metallic materials

• Development of an economic LCA model allowing for clear economic indicators that enable the affordability versus light-weighting trade-off


Timing10/12 2013 2014 2015 09/2016

Simulation

Material Development

Manufacturing

Characterisation & Testing

Validation & Proof of Feasibility

Life Cycle Assessment

Module Design

Dissemination & Exploitation


Expected Results / Research performance indicators

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 *


Expected Results / Research performance indicators

Elaboration of cost-efficient joining and manufacturing technologies for new materials suitable for medium-scale production (50.000 units/year) Elaboration energy-efficient processes enabling a CO2 foot print equal or lower that of

conventional solutions made from metals

Elaboration of continuous manufacturing processes for new, advanced lightweight materials reducing cycle times by half or better

reduced manufacturing costs at least 20% lower than the SotA validated

Elaboration of function integration into lightweight modules Number of parts of a sub-system reduced such weight savings of 20% or more can be

achieved with same or higher functionality

Proof of feasibility that integration of smart function such as smart damping, active systems for NVH or monitoring leads to overall weight savings of 20%

New, advanced lightweight materials implemented in the optimal design of electric vehicles

LCA implemented as parameter in the vehicle design process


Dissemination – The SEAM cluster

Modeling and testing for improved safety of key composite structures in

alternatively powered vehicles

Coordinator: fka

Safe small electric vehicles through advanced simulation methodologies

Coordinator: ViF

Coordinator: VW

Advanced high volume affordable lightweighting for futureelectric vehicles

Coordinator: Fraunhofer LBF

Enhanced lightweight design byadvanced lightweight materials

Biggest European RTD-cluster on lightweight design

47 partner from 10 countries, about 19 Mio. € funding

Joint dissemination activities between the SEAM projects

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

Liaison TeamCRF, VW, fka, ViF, LBF, ika,

B&W

www.seam-cluster.eu


Contact

Project website www.project-enlight.eu

Email [email protected]

Thilo Bein

Fraunhofer LBF

Bartningstr. 47

D-64289 Darmstadt

Phone +49 6151 705 463

Fax +49 6151 705 214

E-Mail [email protected]

Internet www.lbf.fraunhofer.de

The ENLIGHT Project · Space frame design Modularity in battery and BiW design SuperLIGHT-Car...

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