alive, enlight & epsilon final workshop · alive, enlight & epsilon final workshop ......
Post on 02-Sep-2018
220 Views
Preview:
TRANSCRIPT
© 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
© epsilon consortium 2016
Funded by
the Seventh Framework Programme
of the European Union
Johannes Stein / Final Event 2
Agenda
Package Investigation
Structural BIW Concept
Vehicle Safety Investigation
Summary and Outlook
© epsilon consortium 2016
Funded by
the Seventh Framework Programme
of the European Union
Johannes Stein / Final Event 3
Package Investigation
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
© epsilon consortium 2016
Funded by
the Seventh Framework Programme
of the European Union
Johannes Stein / Final Event 4
Package Investigation
Package concept Drivetrain concept
Chassis concept
BiW concept
Vehicle concept
Cooler Inverter; DC/DC Motor
HV Battery Charger
Transmission
MC Pherson
Omega beam
© epsilon consortium 2016
Funded by
the Seventh Framework Programme
of the European Union
Johannes Stein / Final Event 5
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
Package Investigation
© epsilon consortium 2016
Funded by
the Seventh Framework Programme
of the European Union
Johannes Stein / Final Event 6
Agenda
Package Investigation
Structural BIW Concept
Vehicle Safety Investigation
Summary and Outlook
© epsilon consortium 2016
Funded by
the Seventh Framework Programme
of the European Union
Johannes Stein / Final Event 7
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
Structural BIW Concept
© epsilon consortium 2016
Funded by
the Seventh Framework Programme
of the European Union
Johannes Stein / Final Event 8
Structural BIW Concept
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
© epsilon consortium 2016
Funded by
the Seventh Framework Programme
of the European Union
Johannes Stein / Final Event 9
Structural BIW Concept
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
© epsilon consortium 2016
Funded by
the Seventh Framework Programme
of the European Union
Johannes Stein / Final Event 10
CFRP-Al-Space-Frame
Structurally integrated rear seat Maximising BIW stiffness
Structurally integrated battery
Structural BIW Concept
Conceptual lightweight design
© epsilon consortium 2016
Funded by
the Seventh Framework Programme
of the European Union
Johannes Stein / Final Event 11
-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
Structural BIW Concept
© epsilon consortium 2016
Funded by
the Seventh Framework Programme
of the European Union
Johannes Stein / Final Event 12
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
Structural BIW Concept
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
© epsilon consortium 2016
Funded by
the Seventh Framework Programme
of the European Union
Johannes Stein / Final Event 13
Agenda
Package Investigation
Structural BIW Concept
Vehicle Safety Investigation
Summary and Outlook
© epsilon consortium 2016
Funded by
the Seventh Framework Programme
of the European Union
Johannes Stein / Final Event 14
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
Vehicle Safety Investigation
© epsilon consortium 2016
Funded by
the Seventh Framework Programme
of the European Union
Johannes Stein / Final Event 15
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
© epsilon consortium 2016
Funded by
the Seventh Framework Programme
of the European Union
Johannes Stein / Final Event 16
Vehicle Safety Investigation
Euro NCAP full width rigid barrier front crash
video
© epsilon consortium 2016
Funded by
the Seventh Framework Programme
of the European Union
Johannes Stein / Final Event 17
Vehicle Safety Investigation
Euro NCAP offset deformable barrier front crash
video
© epsilon consortium 2016
Funded by
the Seventh Framework Programme
of the European Union
Johannes Stein / Final Event 18
Euro NCAP moveable deformable barrier side crash
Vehicle Safety Investigation
video
© epsilon consortium 2016
Funded by
the Seventh Framework Programme
of the European Union
Johannes Stein / Final Event 19
Euro NCAP side pole crash
Vehicle Safety Investigation
video
© epsilon consortium 2016
Funded by
the Seventh Framework Programme
of the European Union
Johannes Stein / Final Event 20
FMVSS 216 roof test
Vehicle Safety Investigation
video
© epsilon consortium 2016
Funded by
the Seventh Framework Programme
of the European Union
Johannes Stein / Final Event 21
FMVSS 301 offset deformable barrier rear crash
Vehicle Safety Investigation
video
© epsilon consortium 2016
Funded by
the Seventh Framework Programme
of the European Union
Johannes Stein / Final Event 22
Vehicle Safety Investigation
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
© epsilon consortium 2016
Funded by
the Seventh Framework Programme
of the European Union
Johannes Stein / Final Event 23
Vehicle Safety Investigation
High speed video: reduced front structure - full width rigid barrier
video
© epsilon consortium 2016
Funded by
the Seventh Framework Programme
of the European Union
Johannes Stein / Final Event 24
Vehicle Safety Investigation
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
© epsilon consortium 2016
Funded by
the Seventh Framework Programme
of the European Union
Johannes Stein / Final Event 25
Agenda
Package Investigation
Structural BIW Concept
Vehicle Safety Investigation
Summary and Outlook
© epsilon consortium 2016
Funded by
the Seventh Framework Programme
of the European Union
Johannes Stein / Final Event 26
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
© epsilon consortium 2016
Funded by
the Seventh Framework Programme
of the European Union
Johannes Stein / Final Event 27
Summary and Outlook
Prototyping
© epsilon consortium 2016
Funded by
the Seventh Framework Programme
of the European Union
Johannes Stein / Final Event 28
Summary and Outlook
Prototyping
© epsilon consortium 2016
Funded by
the Seventh Framework Programme
of the European Union
Johannes Stein / Final Event 29
Summary and Outlook
© epsilon consortium 2016
Funded by
the Seventh Framework Programme
of the European Union
Johannes Stein / Final Event 30
Thank you for your attention!
Funded by
the Seventh Framework Programme
of the European Union
© epsilon consortium 2016
Funded by
the Seventh Framework Programme
of the European Union
Johannes Stein / Final Event 31
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 stein@ika.rwth-aachen.de
top related