The ENLIGHT Project. Enhanced Lightweight Design. Introduction of project rationale, approach and scope SCP2-GA

Transcription

1 The ENLIGHT Project Enhanced Lightweight Design SCP2-GA Introduction of project rationale, approach and scope ENLIGHT 2012 Slide No. 1

2 General Information Project full title: Enhanced Lightweight Design (ENLIGHT) THEME [GC.NMP GC.NMP ] [Innovative advanced lightweight materials for the next generation of environmentally-friendly electric vehicles], Grant Agreement No Coordinator: Fraunhofer LBF, Thilo Bein Start Date of contract: 01/10/2012 Duration: 48 months Total Budget: Funding: 10,9 MEUR 7,1 MEUR ENLIGHT 2012 Slide No. 2

3 Partners NL DSM Airborne D GB Jaguar Land Rover University of Warwick Fraunhofer LBF Volkswagen Benteler ika PE International Tecnaro S Volvo Oxeon Swerea SICOMP A AIT B KU Leuven F Renault P IDMEC E Bax & Willens Sistemas y Procesos Avanzados I CRF Magneti Marelli Università degli Studi di Firenze ENLIGHT 2012 Slide No. 3

4 Motivation Lightweight as development target to meet the CO 2 targets of ICE-driven cars (-100 kg = 8.5 gco 2 /km) -10% to compensate for the mass of the battery Base data: Affenzeller, AVL Mass reduction: > 250 kg Vehicle mass [kg] but with same safety and comfort to reduce the mass of the battery to extend the range of HEV/FEV ENLIGHT 2012 Slide No. 4

5 Motivation - Mass vs. energy for zero-emission vehicles 10 kwh ENLIGHT 2012 Slide No. 5

6 Motivation - Trend towards multi-material design Source: M.Goede, VW Group Research, SLC ENLIGHT 2012 Slide No. 6

7 Concept SmartBatt Fully integrated battery housing Lightweight battery concept New materials for battery systems SuperLIGHT-Car Economic demonstration of multimaterial vehicle structures for high-volume produced combustion cars ELVA Concept of light BiW for EV s Space frame design Modularity in battery and BiW design Source: SuperLIGHT-Car project, 2009 Source: Fraunhofer LBF, SmartBatt project Source: ELVA project, 2013 MATISSE Modeling and testing Safety of composite structures ALIVE High volume Low weight Low costs Source: M. Kurz, Volkswagen Group Research, K-EFFG/L, 2013 ENLIGHT medium volume Novel materials Low weight SafeEV Modeling and testing of small EVs Safety of vulnerable road users ENLIGHT 2012 Slide No. 7

8 Objectives Development of highly innovative lightweight / low embedded CO 2 materials for their application in medium-volume automotive production ( 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 multiparameter 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 ENLIGHT 2012 Slide No. 8

9 Weight Targets Module Benchmark EV (Nissan Leaf) SLC impact ALIVE ENLIGHT % reduction over ALIVE % reduction over SLC % reduction over benchmark EV BiW (medium risk) % -33.8% -53.7% BiW (high risk) % -39.9% -57.9% Chassis % -44.0% -44.0% Heavy interior % -40.0% -40.0% Hang-on parts % -40.7% -40.7% Overall (best case) % -40.8% -48.7% Overall (worst case) % -37.5% -45.9% ENLIGHT 2012 Slide No. 9

10 Work Structure vehicle concepts from ELVA module design material modeling & simulation material development manufacturing characterisation & testing advanced hybrid materials fibre-reinforced plastics composites renewables L C A & E L V validation & demonstration front-end doormodule suspension sub-frame firewall central floor ENLIGHT 2012 Slide No. 10

11 WP 1 Module Design conceptual design of selected modules conceptual design of selected modules doors / enclosures front module: increased crash performance firewall & cockpit subframe & suspension: function integration and improved NVH door/enclosures: function, integration, increased crash performance and improved NVH cockpit & firewall: function integration, improved acoustics front module 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 central floor module subframe & suspension ENLIGHT 2012 Slide No. 11

12 WP 2 Simulation Material and vehicle simulation Development, calibration and validation of material models that allow the description of the material behaviour in all relevant simulation environments Validation and calibration of material models by mechanical testing Simulation and optimisation of attributes on module level ENLIGHT 2012 Slide No. 12

13 WP 3 Material Development Development of novel lightweight materials allow manufacture at medium production volumes provide affordable vehicle solutions have added functionality and/or increased safety ENLIGHT 2012 Slide No. 13

14 WP 4 Manufacturing Adapted manufacturing technologies for novel lightweight materials 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 welded stiffeners Consideration of a production volume of about modules per year. ENLIGHT 2012 Slide No. 14

15 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 ENLIGHT 2012 Slide No. 15

16 WP 6 Validation / Proof of Feasibility Validation of weight targets and manufacturing concepts 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 ENLIGHT 2012 Slide No. 16

17 WP 7 LCA Life-cycle analysis and life-cycle cost assessment Assessment and comparison of the CO 2 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 ENLIGHT 2012 Slide No. 17

18 Timing 10/ /2016 Module Design Simulation Material Development Manufacturing Characterisation & Testing Validation & Proof of Feasibility Life Cycle Assessment Dissemination & Exploitation ENLIGHT 2012 Slide No. 18

19 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 ( 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 subsystems 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 * ENLIGHT 2012 Slide No. 19

20 Expected Results / Research performance indicators Elaboration of cost-efficient joining and manufacturing technologies for new materials suitable for medium-scale production ( 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 ENLIGHT 2012 Slide No. 20

21 Dissemination The SEAM cluster Safe small electric vehicles through advanced simulation methodologies Enhanced lightweight design by advanced lightweight materials Coordinator: ViF Liaison Team CRF, VW, fka, ViF, LBF, ika, B&W Coordinator: Fraunhofer LBF Advanced high volume affordable lightweighting for future electric vehicles Coordinator: VW Modeling and testing for improved safety of key composite structures in alternatively powered vehicles Coordinator: fka 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 ENLIGHT 2012 Slide No. 21

22 Contact Project website Thilo Bein Fraunhofer LBF Bartningstr. 47 D Darmstadt Phone Fax Internet ENLIGHT 2012 Slide No. 22