WEEVIL project RESOLVE project s final event 2018/04/25

Transcription

1 ULTRALIGHT AND ULTRASAFE EFFICIENT ELECTRIC VEHICLE WEEVIL project RESOLVE project s final event 2018/04/25 1

2 Introduction Needs on road transport at EU cities: Reduce pollution & congestion Potential solution: Daily commute with L category EV Key aspects: Urban, Safe, Comfortable, Attractive, Performant, Affordable WEEVIL project: Individual innovations (applicable on different vehicles) + New vehicle = (next page) 2

3 WEEVIL concept WEEVIL Goals - Urban vehicle - Efficiency - Safety - Comfort - Affordability Encapsulated 3-wheeler in tad-pole configuration Comfort Full encapsulation for environmental protection. Comfortable seating space. No tilting/balancing. Low-cost fibre-reinforced composite structure Safety Composite-made structure with high specific energy absorption. Affordability Low-cost composite structure (radically new high productivity manufacturing process). Efficiency Reduced vehicle weight. Parking cross distance adapter (PINCER) Urban vehicle Reduced footprint for tight roads/parking Joystick parking Urban vehicle Minimum parking footprint Affordability Non autonomous parking Efficient magnet-free motor Efficiency New drive train with improved efficiency over the whole operating range. Affordability Magnet-free motor (no PM associated cost). Interchangeable battery pack Efficiency: New battery management preventing degradation. Affordability: Battery pack interchangeability: batteries from range/manufacturer best fitting user needs/budget. 3

4 1.54 m Specifications, Vehicle layout and Styling (WP2) Objectives: Specifications: size, performance (speed, range). Components layout. Styling: 7 exterior, 3 interior alternatives. Off-the-shelf components. Ergonomic analyses: anthropometry, position and accommodation, roominess, visibility, ingress/egress. Mock-ups: exterior and interior, real size, 2 versions. 90 km/h 10 kw > 80 km 4

5 Specifications, Vehicle layout and Styling (WP2) Feature Buyer s profile Car-like Comfort Description/Value Living in suburban area of big cities, they commute to the city every weekday, can charge the vehicle at home. * Cabin closed provides more comfort and safety than a bike. * Handling & Manoeuvrability as 4-wheel car. * Interior trim, feature, devices should be competitive to other same price range L category vehicle. Motorbike-like Parking-ability Autonomy range / Charge Affordable Price (Stress-less Commuter direction) * Perpendicular parking in congested city, like bike is possible. (Pincer system) * Parking process including in-egress is as easy as bike. (Joystick Parking system) * 80 km (at least). * 4 hours NC & 30 min. (80%) QC 10 k including VAT (battery lease, etc. TBD) (VAT depends on country, price without VAT to be used for the Business Case) 5

6 Specifications, Vehicle layout and Styling (WP2) Final style for prototype 6

7 Objective: Safe, light, affordable vehicle structure. Vehicle chassis and structure (WP3) Glass-fibre reinforced composite structure: 3x Specific Energy Absorption (SEA) than typical metal parts used in the crash structures of automobiles. New ultraviolet (UV)-cured pultrusion process: reduced cost. Result: A strong, durable and light weight structure design. Structural integrity target achieved for 40km/h frontal crash target (WP8). Chassis (WP3) and upperbody (WP7) structure manufacturing started. Physical test to be conducted at early

8 Vehicle chassis and structure (WP3) 8

9 Vehicle chassis and structure (WP3) Limitations of the composites for a cost-effective industrialization High cost of the raw materials Low productivity of the manufacturing processes Low automation (High labour cost) How can we solve the disadvantages of traditional pultrusion? Pultrusion Change the paradigm of traditional pultrusion and cure the profile out of the die Continuous process High productivity Low influence of workforce Control of theresin percentage High mechanical properties in the longitudinal direction Alternative fast curing method is needed Ultraviolet curing (UV) Constant cross section High pulling forces High investment of machinery Limited to straight profiles M. MUSSELMAN World Pultrusion Conference Report., 2010 Process restricted to constant radii Low productivity rates High pulling forces There are some variants but Curing inside the die 9

10 Vehicle chassis and structure (WP3) Out of die UV cured pultrusion (curved profiles) 10

11 Electric motor (WP4) Objectives: compact, efficient, affordable. Magnet-free motor: no rear-earth, robust, efficient at wide speed range. Integrated gearbox: compactness. Integrated electronic driver: 2 power cables and 1 control connector interface Individual pole control: fault tolerance. Result: 11

12 Objectives: Battery system (WP5) Interchangeable battery-pack ( battery swop): - Different chemistries, performances, prices. - Easy to remove. - Open communication protocol, standardized battery-vehicle interface. Efficient: ad-hoc BMS, passive and active balancing, high accuracy and temperature monitoring to reduce degradation & increase efficiency. Ready to market. Results: BP Cells Chemistry Size (V) (A h) (KW h) Price ( ) #1 Sinopoly LiFePo4 Prismatic 76,4 66 5, #2 Kokam NMC Pouch , % +54 % +88 % 12

13 PINCER system (WP6) Objectives: reduced footprint, stability Wheels separation variation mechanism. Steering, suspension, and brakes compatible with PINCER while possessing good riding and dynamic behaviour when the mechanism is open. Results: Quarter cart tests: damper and suspension. PINCER tests: PINCER mechanism and steering. 13

14 PINCER system (WP6) High amplitude, low Hz, quarter car test PINCER test 14

15 Joystick parking concept Objectives: Minimum footprint parking. Simple, reduced cost ! PINCER Driver get out from the car Move slowly by Joystick Perpendicular parking done! 15

16 Objectives: Vehicle fabrication and integration (WP7) Subsystems fabrication: upperbody structure, body panels, etc. Electrification. Vehicle assembly. Subsystems control calibration. Vehicle functional assessment. Body on frame 4 e-motor and GBX Interiors Pincer and front suspension Chassis and battery pack 16

17 Vehicle fabrication and integration (WP7) Aluminium upperbody structure GFRP body panels Input CAD data Tooling engineering 4 Milling of moulds 17

18 Objectives: Vehicle validation and homologation (WP8) Vehicle prototype performance validation. Safety analysis : crash tests Vehicle homologation: guidelines and decisions (performance, safety, ) - Approval and safety requirements for L5e-A category vehicle. - Parking places and curbs in European cities. - Requirements for vehicle lights, registration plate, bumper, front and rear protective structures, doors, steering, 18

19 Vehicle validation and homologation (WP8) Partial crash tests 19

20 End on May

21 WEEVIL Consortium Project coordination Vehicle manufacturer Vehicle styling Battery system Vehicle structure Pincer system Composite structures Electric motor Test & homologation 21