Sponsors. Lyndon Sanders. Director & General Manager Axon Automotive

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Easter Nichols
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1 Sponsors Lyndon Sanders Director & General Manager Axon Automotive

A small, safe and light electric car Presented by: Lyndon

600kg electric city car Will pass EuroNCAP crash test Be attractive Be functional viable Be commercially viable The benefits of an M1 in the package of an L7 Concept Specification Sheet References

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.

59 (GKN) Front Axle McPherson Rear Axle solid axle Front Tires 145/65 R15 Rear Tires 175/55 R15 Turning Cycle 9 m NCAP Rating 4 Stars Exterior Dimensions Interior Dimensions Functional Objectives

3 600kg electric city car Will pass EuroNCAP crash test Be attractive Be functional viable Be commercially viable The benefits of an M1 in the package of an L7 Concept Specification Sheet References Renault Twizzy L: 2337 mm W: 1191 mm H: 1461 mm Tazzari Zero L: 2880 mm W: 1560 mm H: 1425 mm Smart Fortwo E L: 2695 mm W: 1559 mm H: 1542 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 (1-100km/h) <10 s Electric Motor 80 kw (Bosch) Gearbox Ratio 1:9.59 (GKN) Front Axle McPherson Rear Axle solid axle Front Tires 145/65 R15 Rear Tires 175/55 R15 Turning Cycle 9 m NCAP Rating 4 Stars Exterior Dimensions Interior Dimensions Functional Objectives Length 3000 mm Headroom Driver 980 mm Car sharing capability Width 1530 mm Headroom Co-Driver 980 mm Mainly for urban commuting Height 1480 mm Headroom 2nd Row 850 mm Modularity for families Wheelbase 2040 mm Shoulder Room Front 1140 mm Easy to use Front Track 1295 mm Shoulder Room Rear 880 mm Agile in urban context Axon Automotive Ltd 2017 All rights reserved Rear Track 1257 mm Trunk Volume l High connectivity 3

4 The challenges Styling for such tight packaging is not easy Making use of the extra flexibility of an M1 to give better functionality but brings tougher regulatory standards A hybrid body structure that is light enough is not intuitively cost effective A car this size has very little front structure to achieve deceleration For an electric car there is a lot of mass in the battery that the limited remaining structure has to control in crash Axon Automotive Ltd 2017 All rights reserved 4

6 Better functionality Smart Fourtwo (Electric) L:2695 mm W:1559 mm H: 1542 mm Kerb weight: 1085kg Seats: 2 Epsilon L:3000 mm W:1530 mm H: 1480 mm Kerb weight: 600kg Seats: 2+1 Renault Twizy L:2337 mm W:1191 mm H: 1461 mm Kerb weight: 474kg Seats: 1+1 Axon Automotive Ltd 2017 All rights reserved 6

Controlling costs Front and rear sacrificial aluminium crush zones to manage repair and insurance costs Axontex space frame passenger cell to give low cost carbon fibre chassis Braided beams give

7 Controlling costs Front and rear sacrificial aluminium crush zones to manage repair and insurance costs Axontex space frame passenger cell to give low cost carbon fibre chassis Braided beams give very high material utilization Scott Bader Crestapol resin systems give good cost control and short cycle times VARTM runs on very low tooling and capital costs Bonded structure means production methods can be tailored to the right cost structure across a range of planned volumes from niche production to > 100,000 cars a year Axon Automotive Ltd 2017 All rights reserved 7

Next steps on costs Reduce the number of panels by integrating where possible Convert some panels to discontinuous fibre Convert some panels to technical GRP

8 Next steps on costs Reduce the number of panels by integrating where possible Convert some panels to discontinuous fibre Convert some panels to technical GRP Review cross vehicle beam profile to remove material (carbon) Design for off-the shelf front and rear suspensions Axon Automotive Ltd 2017 All rights reserved 8

10 Crash analysis Good News: Passenger cell remains intact No intrusion into foot-well Battery remains protected and secure Crash pulse profile and size is a good match for FEA model More work needed:? Can we find a better alternative than aluminium? Can we make the lower structure absorb more energy? Improvement of crash pulse to reduce long-duration accelerations early on. Axon Automotive Ltd 2017 All rights reserved 10

Designing front crash beams that extend through the length of the car to transmit energy better into the

11 Next steps on crash 1. Converted upper and lower front beams to Axontex 1. Samples built and tested at Millbrook 2. Tested sample was front crash structure and bulkhead only 2. Designing front crash beams that extend through the length of the car to transmit energy better into the whole structure 3. Reviewing design of lower crash members to give more progressive energy absorption Axon Automotive Ltd 2017 All rights reserved 11

com/ HPL Proto vehicle assembly http://www.

13 Thank You Q&A Visit us to see the new front crash structure in Hall 4, stand 401 Watch the video of the finished car on the track at: Find out more at: Axon Automotive Ltd 2017 All rights reserved 13

epsilon Structural Design of Body and Battery Housing

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