Faculty of Mechanical Science and Engineering, "Friedrich List" Faculty of Transport and Traffic Sciences

Transcription

1 Faculty of Mechanical Science and Engineering, "Friedrich List" Faculty of Transport and Traffic Sciences Funktionsintegrativer Systemleichtbau eine Schlüsseltechnologie für die Mobilität von morgen Function-integrative System Lightweight Engineering a Key Technology for the Mobility of Tomorrow Prof. Dr.-Ing. habil. Maik Gude, Prof. rer. Nat. Hubert Jäger, Prof. Dr.-Ing. Niels Modler Innovationskongress Technische Universität in Breslau, Mail: ilk@mailbox.tu-dresden.de Web: tu-dresden.de/mw/ilk Tel: Fax: Mobility of Tomorrow Basic conditions Increasing environmental requirements Changing customer behaviour Linked multimodal transport systems New individualised mobility systems Resource efficient & low emissions Flexible & Linked Steady & Safe Affordable & Modern Daimler Tesla Google The individualised mobility of tomorrow is increasingly dominated by electrically driven vehicles 2 1

2 Challenges for the Electromobility Distance Infrastructure Vehicle price ZoePionierin Tesla Acceptance Ecology Starterset-elektromobilitaet T-online 3 Challenges for the Electromobility Distance Infrastructure Acceptance ecology Necessary Actions Upgrading of energy infrastructure Extension of communication systems Development of linked traffic systems Realisation of intelligent driver assistance systems Introduction of autonomous driving systems Adaption of legislation Development of new drive-train technologies and batteries Function integrating lightweight design What Key function is assumed by the function integrating lightweight-design relating to the existing challenges? 4 2

3 Challenge: Distance Fundamental approaches, e.g.: Distance Performance-increased battery systems Efficient engines Alternative power train systems using hydrogen or fuel cell Significant mass reduction of the whole vehicle 5 Challenge Distance: Integrative compact battery-system Cost-effective battery-system with highest power density Modular supporting design based on Li-Ion cells Flexible designable space-saving packaging Use of cheap cells (Tesla standard) Distance source: SCABA 6 3

4 Challenge Distance: Function integrating systemic lightweight design Distance Function integrating Multi-Material Design for complex body components in electric vehicles Innovative sandwich-sheets in Multi-Material- Design with local fibre reinforcement and metallic layers (magnesium and steel) Efficiently combined manufacturing process combining injection and compression moulding Highly integrative hybrid floor assembly source: ThyssenKrupp 7 Challenge Infrastructure Infrastructure Fundamental approaches, e.g.: Dense network with loading facilities Easy consumption recording and payment Comfortable loading Determination of standards 8 4

5 Challenge Infrastructure: Part-integrated wireless inductive loading Development of a simulation framework for an efficient technical configuration of wireless loading units Infrastructure Development of systems with an easy and quick integration of a receiving unit Development of wireless inductive loading units with transmission performances of W; 3,6 kw and 11 kw 9 Challenge Fundamental approaches, e.g.: Development and usage of cost effective materials Realisation of highly integrative designs Efficient manufacturing processes capable for mass production Use of the available material diversity Shortening the development cycles Realisation of specific electromobility-designs 10 5

6 Challenge : Cost efficient highly integrated thermoplastic design Collaborative Research Area SFB 639: Function integrated vehicle system FiF Reduction of parts by using highly integrative design methods Intelligent stiffness and strength optimised design allows the use of cost effective composites (PP-GF) Combined manufacturing process: casting and forming (cycle time < 1min) 11 Challenge : Integrated motor design Compact and efficient electric motor Motor and power electronics as a unit Compact lightweight design, 15 % mass reduction Reduction of parts (complex cabling reduced) Use of cost effective magnetic materials (no use of rare earths) 12 6

7 Challenge : Cost-effective prototype and mould manufacturing Large-series generative manufacturing Additive and subtractive manufacturing in a hybrid production cell Extrusion-unit as a switchable tool head for the milling production cell Re-Use of recycled plastics Reduction of production times for moulds and forms Vision: generative manufactured support structures quicker higher temperature stability costreduction 13 Challenge : Reduction of development cycles Quality assured, virtual development of process chains for the manufacturing of hybrid lightweight structures Linking of established individual processes to a closed process chain Enhancing the degree of automation Surface modification of an enhanced adhesion of different materials (e.g. steel and plastics) Realisation of virtual and real quality assurance with a coupled process simulation 14 7

8 Challenge : Efficient manufacturing processes capable for mass production Integrative manufacturing of lightweight sandwich structures for large-series Combination of the processes beadfoaming and injection moulding Development of highly integrative beadfoamthermoplastic-composites Development of a manufacturing plant for a steam-free beadfoam production Source: Krallmann Hybrid lightweight sandwich structures 15 Challenge Acceptance Acceptance Fundamental approaches, e.g.: Broad product portfolio Attractive vehicles without losses comparing to current products Easy use Releasing new trends 16 8

9 Challenge Acceptance: Consistent lightweight design for sporty electric vehicles Electric car with 3 doors and 4 seats for the urban area Low weight due to diverse function integration and an innovative material mix Part-integration: car body consists of only 63 components by the use of integral car design Crash-resistant floor structure secures inmates and battery system Acceptance E-Vehicle InEco 17 Challenge Ecology Fundamental approaches, e.g.: Ecology Sustainable energy production Resource-efficient use of materials Waste reduction Relief of the traffic routes Gapless Life-Cycle-Assessment (LCA) Holistic traffic concepts 18 9

10 Challenge Ecology: Resource-efficient large-series manufacturing processes Recycling-technologies for CFRP-treatment Ecology Material separation and sorting Resource-efficient manufacturing process Integrative Sandwich-structures with re-used materials Manufacturing and recycling strategies for the electromobility considering the re-use of lightweight structures 19 Elektromobility at the ILK Vehicledemonstrator InEco Showcase: Electromobility Pedelecdemonstrator nam-e Vehicledemonstrator etrust Inductive loading Vehicledemonstrator FiF Highperformanc e rim Electric Drive (Motorbrain) 20 10

11 Thanks InEco -Projekt: Das Projekt wurde aus Mitteln der Europäischen Union und des Freistaates Sachsen finanziert. FOREL, LEIKA, ReLei, SamPa: Die Projekte werden mit Mitteln des Bundesministeriums für Bildung und Forschung (BMBF) im Rahmen Forschung für die Produktion von morgen und mit Mitteln aus dem Energie- und Klimafonds gefördert und vom Projektträger Karlsruhe betreut. MotorBrain: This project has received funding from the European Union s Seventh Framework Programme for research, technological development and demonstration under grant agreement no EmiD: Das Projekt EmiD Elektromobilität in Dresden" ist eines von rund 40 Projekten im Schaufenster Bayern-Sachsen ELEKTROMOBILITÄT VERBINDET und wird mit Euro vom Freistaat Sachsen im Rahmen der Schaufensterinitiative der Bundesregierung gefördert. edas: This project has received funding from the European Union s Seventh Framework Programme for research, technological development and demonstration under grant agreement no OSEM-EV: This project has received funding from the European Union's Horizon 2020 Programme under Grant Agreement No