epsilon Small Urban Passenger Vehicle with CFRP-Aluminium Spaceframe Body Architecture

Transcription

1 Composite Europe 2016 epsilon Small Urban Passenger Vehicle with CFRP-Aluminium Spaceframe Body Architecture Düsseldorf, 30. November 2016 Dipl.-Ing. Ralf Matheis, Dipl.-Ing. Johannes Stein, Dipl.-Ing. Kristian Seidel, Dipl.-Ing. Sven Faßbender, Dr.-Ing. Peter Urban, Univ.-Prof. Dr.-Ing. Lutz Eckstein Institut für Kraftfahrzeuge RWTH Aachen University Slide No. 1

2 Agenda Motivation Project Overview Concept Investigation Development Demonstrator Vehicle Summary Slide No. 2

3 Project Overview Motivation Urbanisation is closely connected to the evolution of mobility 74% of European population lives in urbanised areas Urban population will increase from 3.6 billion to 6.3 billion between 2011 and 2050 New challenges in terms of congestion as well as pollution and noise emissions Shared mobility and services become more important Demografic change Connectivity Individualisation of mobility needs Crime Climate change Emissions Urbanisation Accidents MOSKOW VIENNA OSLO ZURICH BIRMINGHAM FRANKFURT STOCKHOLM AMSTERDAM LISBON MADRID BRUSSELS COPENHAGEN NAPLES LONDON PARIS CITY ATHEN BERLIN MILANO BARCELONA STOCKHOLM Congestion COLOGN MARSEILLE MUNICH TORINO BUDAPEST ROME LYON RIGA HAMBURG ANTWERP ST. PETERSBURG BIRMINGHAMICH Limited resources Public debt Rising costs of energy and fuel Slide No. 3

4 Agenda Motivation Project Overview Concept Investigation Development Demonstrator Vehicle Summary Slide No. 4

5 Project Overview Consortium Funded by European Commission s 7 th Framework Programme Exterior and interior finish small Electric Passenger vehicle with maximized Safety and Integrating a Lightweight Oriented Novel body architecture Funding 2.5 Million Euro (project total) Project Duration November 2013 to February 2017 Prototyping Full vehicle integration and assembly Project coordination Concept investigation Exterior & interior design Package Body design (CAE, CAD) Drivetrain layout HMI CFRP rear axle Drivetrain layout Energy efficiency HVAC Integral safety Battery integration Crash testing Active crash structures and restraints Business case study Chassis design & build Vehicle dynamics tests Slide No. 5

6 Agenda Motivation Project Overview Concept Investigation Development Demonstrator Vehicle Summary Slide No. 6

7 Concept Investigation Objectives L7e M1 Renault Twizy L: 2335 mm W: 1228 mm H: 1454 mm Efficiency Safety, comfort Smart Fortwo E L: 2695 mm W: 1559 mm H: 1565 mm Designing and prototyping the urban small electric vehicle of Appealing driving performance Affordable costs Lighter, more energy-efficient and compact than today's sub-compact cars Higher safety, transport capacity and comfort than powered two-wheelers Closing the gap between ultra light vehicles (L7e) and conventional cars (M1) Slide No. 7

8 References Concept Investigation Package Concept Specification Sheet 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 Technical Specs and Targets Curb weight 600 kg Gross vehicle weight 850 kg Battery capacity 15.6 kwh c d 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 2 nd row Shoulder room front Shoulder room rear Trunk volume Functional Objectives Suitability for car sharing 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 Slide No. 8

9 Concept Investigation Package Final Package Package concept Drivetrain development Vehicle concept Chassis development Cooler Charger HV battery Inverter; DC/DC Transmission Motor BiW development Slide No. 9

10 Agenda Motivation Project Overview Concept Investigation Development Demonstrator Vehicle Summary Slide No. 10

11 Development 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 CFRP-Al-space-frame Structurally integrated battery Structurally integrated rear seat Aluminium CFRP Slide No. 11

12 Development Structural BIW concept Body in White CFRP-aluminium space frame architecture CRFP space frame enclosing the passenger compartment Axontex technology by partner Axon LPDE foam cores overbraided with HT carbon fibre Additional braiding process leads to multi-chamber cross section Filling with PU resin by VARTM in a tool Curing in autoclave Aluminium extrusion profile for front, rear and side deformation zones CFRP beam cross section Foam core Slide No. 12

13 Development Structural BIW concept Body in White CFRP-Al-Space-Frame Tailored CFRP shear panels and nodes GFRP exterior panels (non-structural) 21 kg 10 % 8 kg 4 % BIW Doors and closures 35 kg 17 % 35 kg 16 % 112 kg 53 % Exterior Glazing Hang-on parts/brackets Slide No. 13

14 Development Structural BIW concept Static load cases Bending Stiffness Torsion Stiffness kn c Bending 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 Slide No. 14

15 Development Structural BIW concept 1 Crash load cases # 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 Slide No. 15

16 Development Structural BIW concept Euro NCAP full width rigid barrier front crash video Slide No. 16

17 Development Chassis Front and rear axle McPherson front suspension and steering system have been derived from the ones of a donor vehicle with minor adaptations. An Omega beam rear axle has been specifically designed for the epsilon vehicle with the aim of: assuring a good K&C performance weight reduction (37%) with hybrid metal/cfrp solution : Middle section (CFRP) 2: Connection with central joint (metal) 3: Connection between middle and side section 4: Side section (metal) 5: Wheel trunk (metal) 6: Connection with the Watt-linkage (metal) [CRF] Slide No. 17

18 Development Drivetrain Drivetrain architecture Inverter/converter Transmission Electric motor Driving efficiency and performance determined for WLTP-C3 in HIL test: 156 km driving 90% SOC to 15% SOC 76 Wh/km energy demand 8.9 s to 100 km/h Integrated power distribution unit High voltage battery Cell type: Panasonic 18650PF 110 kg (25% less than liquid-cooled version) Three additional electric connectors for fast charging, PTC heater, refrigerant compressor Voltage (nom.): 367 V Energy content: 15.6 kwh (DoD of 75%) Slide No. 18

19 Agenda Motivation Project Overview Concept Investigation Development Demonstrator Vehicle Summary Slide No. 19

20 Demonstrator Vehicle Prototyping Prototyping Body structures Full vehicle integration Drivetrain system Omega beam Slide No. 20

21 Demonstrator Vehicle Testing Testing video Slide No. 21

22 Agenda Motivation Project Overview Concept Investigation Development Demonstrator Vehicle Summary Slide No. 22

23 Summary The epsilon concept shows a prototype for an urban small electric vehicle of Specifically designed for the typical transport tasks in urban areas, based on a scenario and market analysis The minimalistic vehicle concept shows a safe & efficient urban mobility concept. A running prototype vehicle has been built to demonstrate a new vehicle class to possible customers and stakeholders. epsilon closes the gap between L7e vehicles and conventional cars (M1), is lighter and more energy efficient than today's sub-compact cars, offers higher safety, transport capacity and comfort compared to powered two-wheelers (PTWs) and ultra light vehicles. Slide No. 23

24 Thank you for your attention! Funded by the Seventh Framework Programme of the European Union On behalf of the epsilon team Slide No. 24

25 Contact Dipl.-Ing. Ralf Matheis fka Forschungsgesellschaft Kraftfahrwesen mbh Aachen Steinbachstr Aachen Germany Phone Fax matheis@fka.de Internet Slide No. 25