7/30/2019 lightweight design EV

1/13

Fundedby

InnoMateria 2012

Cologne, 22 Mai 2012

Collins Ntchouzou, Volkswagen AGAlexander Schiebahn, ISF

7/30/2019 lightweight design EV

2/13

Light-eBody consortium 201222.05.2012Slide No. 2C. Ntchouzou, A. Schiebahn/ InnoMateria 2012

Fundedby

Development of an innovative multi-material lightweight car body

Intensive use of profiles made from (ultra) high strength steel for the vehicle

load bearing structure

Lightweight panels from low density materials (aluminium, plastics, metal-plastic-hybrids or sandwich material)

Integration of the battery structure in the vehicle structure as load bearingelement

Details analysis of the used materials, manufacturing technologies and

joining technologies CAE method development to enable a reliable simulation of the material

combination and the joining

Life Cycle Analysis investigations

Light-eBody

Objectives & Design Approach

7/30/2019 lightweight design EV

3/13

Light-eBody consortium 201222.05.2012Slide No. 3C. Ntchouzou, A. Schiebahn/ InnoMateria 2012

Fundedby

Light-eBody

Objectives & Design Approach

Ultra high strength steel vehicle

structure in profile intensive design

Lightweight panels from material with

low density (aluminium or plastics)

Load bearing battery structureSource: Ford

7/30/2019 lightweight design EV

4/13 Light-eBody consortium 201222.05.2012Slide No. 4C. Ntchouzou, A. Schiebahn/ InnoMateria 2012

Fundedby

Light-eBody

Consortium Altair Engineering

Bllhoff

Dow

Ford

Fraunhofer LBF

Hydro Aluminium

Institut fr Kraftfahrzeuge

Institut fr Schweitechnik & Fgetechnik

Laboratorium fr Werkstoff- & Fgetechnik

LINDE + WIEMANN

Rchling Automotive

ThyssenKrupp Steel

Volkswagen

Werkzeugmaschinenlabor

7/30/2019 lightweight design EV

5/13 Light-eBody consortium 201222.05.2012Slide No. 5C. Ntchouzou, A. Schiebahn/ InnoMateria 2012

Fundedby

Light-eBody

Basic Specifications Use case: urban/commute

Seats: 2+3

Range: > 150 km (NEDC)

vmax: 150 km/h

Weight: 1,250 kg

Production: large volume (1,000/d)

Segment: C

7/30/2019 lightweight design EV

6/13 Light-eBody consortium 201222.05.2012Slide No. 6C. Ntchouzou, A. Schiebahn/ InnoMateria 2012

Fundedby

Light-eBody

Topology Optimisation Load Paths Determination of material distribution

within a specified design space

Objective: minisation of complaince

Constraint: 80% volume reduction Frontal impact

Pole impactSide impact

IIHS Side impact

FMVSS 301 Rear impact

Global stiffness

Material distributionDesign space

Load cases

7/30/2019 lightweight design EV

7/13 Light-eBody consortium 201222.05.2012Slide No. 7C. Ntchouzou, A. Schiebahn/ InnoMateria 2012

Fundedby

Plastics

Aluminium

Magnesium

Steel

Light-eBody

Materials & manufacturing technologies

Manufacturing technologiesMaterials

T3 Technology

Tailored Tempering

Rolled forming

Extrusion

Form-Blow-Hardening

Casting

7/30/2019 lightweight design EV

8/13 Light-eBody consortium 201222.05.2012Slide No. 8C. Ntchouzou, A. Schiebahn/ InnoMateria 2012

Fundedby

Research in innovative, high-volume capable

joining technologies for multi-material design

High-speed bolt joining

Spotwelding with elements

Selfpiercing riveting

Examples (1/2):

LWF

LWF

Boellhoff

C. Ntchouzou, T. Olfermann, A. Schiebahn/ InnoMateria 2012

7/30/2019 lightweight design EV

9/13 Light-eBody consortium 201222.05.2012Slide No. 9C. Ntchouzou, A. Schiebahn/ InnoMateria 2012

Fundedby

Research in innovative, high-volume capable

joining technologies for multi-material design

Laser beam welding

Indirect spot-welding

Adhesive bonding / hybridjoining with new structuralepoxies

Examples (2/2):

7/30/2019 lightweight design EV

10/13 Light-eBody consortium 201222.05.2012Slide No. 10C. Ntchouzou, A. Schiebahn/ InnoMateria 2012

Fundedby

Life Cycle Analysis based on ISO 14040

Recycling

Use

ProductionInputEnergy

Raw materials

OutputEmission

Waste

7/30/2019 lightweight design EV

11/13 Light-eBody consortium 201222.05.2012Slide No. 11C. Ntchouzou, A. Schiebahn/ InnoMateria 2012

Fundedby

Conclusions

Topology optimisation was conducted to identify the main load paths

The load bearing structure was split into car body structure and battery structure

Suitable joining techniques for the realisation of this approach are now analysedand developed.

CAE methods for the simulation of the joining of the material combination are in

development

Development accompanying LCA

The integration of the battery structure as load bearing part of the vehicle

structure helps reducing the vehicle weight.

The intensive profile design approach is very promising concerning light weight

and modularity, but the joining remains a big challenge.

7/30/2019 lightweight design EV

12/13 Light-eBody consortium 201222.05.2012Slide No. 12C. Ntchouzou, A. Schiebahn/ InnoMateria 2012

Fundedby

Innovation beginning of the 20th century

3

Worldwide sold vehicles in 2010:

Worldwide demand for motor vehicles willnot exceed one million

solely due to the lack of available

drivers.

> 60 Mio.

Gottlieb Daimler, 1901

Worldwide sold battery electric vehicles in the next decades:

Faith in the future innovation !

> ? Mio.

7/30/2019 lightweight design EV

13/13

Light-eBody consortium 201222.05.2012Slide No. 13C. Ntchouzou, A. Schiebahn/ InnoMateria 2012

Fundedby