epsilon Structural Design of Body and Battery Housing

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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 Johannes Stein / Final Event 1

2 Agenda Package Investigation Structural BIW Concept Vehicle Safety Investigation Summary and Outlook Johannes Stein / Final Event 2

3 References Funded by Package Investigation Renault Twizy L: 2335 mm W: 1228 mm H: 1454 mm Tazzari Zero L: 2880 mm W: 1560 mm H: 1425 mm Smart Fortwo E L: 2695 mm W: 1559 mm H: 1565 mm Vehicle Type Segment M0, Sub-A Seats 2 (M95 th ) +1 (F5 th ) 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 Length Width Height Wheelbase Front track Rear track Interior Dimensions Headroom driver Headroom co-driver Headroom 2nd row Shoulder room front Shoulder room rear Trunk volume Functional Objectives Car sharing capability Mainly for urban commuting Modularity for families Easy to use Agile in urban environment 3100 mm 1500 mm 1460 mm 2040 mm 1295 mm 1257 mm 980 mm 980 mm 850 mm 1190 mm 1080 mm l Johannes Stein / Final Event 3

4 Package Investigation Package concept Drivetrain concept Vehicle concept Chassis concept MC Pherson BiW concept Cooler Charger HV Battery Inverter; DC/DC Motor Transmission Omega beam Johannes Stein / Final Event 4

5 Package Investigation Transmission Inverter/ Converter HVAC-box 12V-battery Radiator and fan AC-charger E-motor Hybrid CFRP-metal rear axle HV-Battery McPherson axle PTC heater Johannes Stein / Final Event 5

6 Agenda Package Investigation Structural BIW Concept Vehicle Safety Investigation Summary and Outlook Johannes Stein / Final Event 6

7 Mass [kg] Funded by Structural BIW Concept Need for lightweight design to achieve epsilon target Volume [m³] Renault Twizy epsilon Smart Fortwo E Mitsubishi imiev VW e-up BMW i3 VW e-golf Nissan Leaf 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] [kg/m³] Johannes Stein / Final Event 7

8 Structural BIW Concept Holistic lightweight design approach Geometrical lightweight design Conceptual lightweight design Material lightweight design Lightweight body Topology optimisation CAD Model Lightweight design by topology optimisation [FRI13] Half monocoque with front and rear end Monocoque on frame Full monocoque Steel Aluminium Magnesium Thermoplastic [NN16] Johannes Stein / Final Event 8

9 Structural BIW Concept Geometrical lightweight design by topology optimisation Package concept Design concept Finite element model 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 BIW design space Topology optimisation BIW 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 BIW lightweight structure Johannes Stein / Final Event 9

10 Structural BIW Concept Conceptual lightweight design Structurally integrated battery CFRP-Al-Space-Frame Structurally integrated rear seat Maximising BIW stiffness Johannes Stein / Final Event 10

11 Structural BIW Concept Material lightweight design CFRP-Al-Space-Frame Tailored shear panels GFRP exterior panels CFRP beam Foam core - 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 Johannes Stein / Final Event 11

12 Structural BIW Concept Weight target full vehicle: 600 kg Weight target body: 210 kg Current weight: 211 kg 66 kg 11 % 60 kg 10 % 96 kg 16 % 168 kg 28 % 210 kg 35 % Body Drive Train Chassis Electronics Interior 35 kg 17 % 21 kg 10 % 35 kg 16 % 8 kg 4 % 112 kg 53 % BIW Doors and closures Exterior Glazing Hang-on parts/brackets Johannes Stein / Final Event 12

13 Agenda Package Investigation Structural BIW Concept Vehicle Safety Investigation Summary and Outlook Johannes Stein / Final Event 13

14 Vehicle Safety Investigation Bending Stiffness Torsion Stiffness c Bending kn mm kn c Torsion z z y x y x Translation locked in Y, Z Translation locked in X, Y, Z Translation locked in Z Translation locked in X, Z Lightweight quality index: L T = m BIW c T A T = 1.38 Johannes Stein / Final Event 14

15 Vehicle Safety Investigation # 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 Johannes Stein / Final Event 15

16 Vehicle Safety Investigation Euro NCAP full width rigid barrier front crash video Johannes Stein / Final Event 16

17 Vehicle Safety Investigation Euro NCAP offset deformable barrier front crash video Johannes Stein / Final Event 17

18 Vehicle Safety Investigation Euro NCAP moveable deformable barrier side crash video Johannes Stein / Final Event 18

19 Vehicle Safety Investigation Euro NCAP side pole crash video Johannes Stein / Final Event 19

20 Vehicle Safety Investigation FMVSS 216 roof test video Johannes Stein / Final Event 20

21 Vehicle Safety Investigation FMVSS 301 offset deformable barrier rear crash video Johannes Stein / Final Event 21

22 Vehicle Safety Investigation Testing: reduced front structure - full width rigid barrier 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 Johannes Stein / Final Event 22

23 Vehicle Safety Investigation High speed video: reduced front structure - full width rigid barrier video Johannes Stein / Final Event 23

24 Force Fx [kn] Force Fx [kn] Funded by Vehicle Safety Investigation Measurement Data FEM Simulation Data Time t [s] Time t [s] Johannes Stein / Final Event 24

25 Agenda Package Investigation Structural BIW Concept Vehicle Safety Investigation Summary and Outlook Johannes Stein / Final Event 25

26 Summary and Outlook 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 Johannes Stein / Final Event 26

27 Summary and Outlook Prototyping Johannes Stein / Final Event 27

28 Summary and Outlook Prototyping Johannes Stein / Final Event 28

29 Summary and Outlook Johannes Stein / Final Event 29

30 Thank you for your attention! Funded by Funded by Johannes Stein / Final Event 30

31 Contact Dipl.-Ing. Johannes Stein Institute for Automotive Engineering (ika) RWTH Aachen University Steinbachstr Aachen Germany Phone Fax stein@ika.rwth-aachen.de Johannes Stein / Final Event 31

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