EUCIA Composites and Sustainability WS Lightweighting research in EU transport projects: the role of composites

Maurizio MAGGIORE

DG RTD H2

19/1/2016

http://www.bbgreen.info/

Electric, air-supported high speed waterbus

Fully carbon composite sandwich hull

MARITIME APPLICATIONS: BB GREEN

Other projects have looked at

superstructures of large ships

Development, production and use of high performance and lightweight materials for vessels and equipment

Challenge

• Exploring new lightweight materials for waterborne • Developing design, construction & production principles

Scope

• Conception, production and use of advanced composites

Expected impact

• Introduce new lightweight materials • Decrease maintenance and life cycle costs • Inputs to relevant regulatory regimes as appropriate

Estimated budget per proposal: EUR 7-9 Mio

Topic MG-2.2-2016 (IA)

http://www.refresco-project.eu/

• Weight per seat for passengers trains from 400kg

to 800kg (some, such as the ICE 2, up to 1100kg)

• Composites used in the front ends of trains and

locomotive, lateral panels, interiors…

• Lack of confidence for structural application

from a void in legislation about requirements,

conformity procedures and acceptance

criteria

• DE-LIGHT (FP6) has proven the feasibility of

structural lightweight materials for rail vehicles.

• Refresco (FP7) - Towards a REgulatory

FRamework for the usE of Structural new

materials in railway CarbOdyshells

RAIL APPLICATIONS

• In Shift2Rail JTI (H2020), a Carbodyshell

Demonstrator will be launched, to demonstrate:

•Weight reduction with energy

consumption benefits

•improved comfort and function

•alternative vehicle concepts

•Increased capacity

• Details in the Multiannual Action Plan

• SLC – Development of multimaterial optimized structures (30-50%

reduction of structure weight expected, equivalent to up to 25 g/km CO2)

– The right material for each part, keeping costs and production rates suitable for mass production

– A 30-50% weight reduction is targeted, with a cost increase of 3-5 €/kg (10 for niche cars)

• LIGHTBUS – Lightweight bus structures

AUTOMOTIVE APPLICATIONS

European Green Cars initiative

• What: One of the three PPP for research and innovation proposed in the European recovery Plan of 2008. EGCI includes three action lines: research, innovation and demand side measures.

• Main RTD priorities:

– Electrification of road and urban transport;

– Improved energy efficiency for heavy-duty vehicles;

– Logistics and co-modality

• Original Funding:

– Up to € 500 million for research + 4B€ EIB loans

Some EGCI statistics (1)

• 115 project running or under negotiation for the whole EGCI, of which around 95 on electrification

• Almost complete coverage of the EGCI roadmap

140

86 65

35

32

25 24

16 7

EC contribution in € million Vehicle System Integration& Demo

Energy Storage

Drive Train & Auxiliaries

ICT and infrastructure

Trucks

Logistic

Grid Integration

other

Range extenders

31

20

19

11

10

8

7

6 3

Number of projects per group Vehicle System Integration& Demo

Energy Storage

Drive Train & Auxiliaries

Logistic

ICT and infrastructure

other

Grid Integration

Trucks

Range extenders

Coordinator: Fraunhofer LBF Total costs: 10,9M€ EC contribution: 7,1M€ Start date: 1/10/2012 Duration: 48 months

Focus: • highly innovative lightweight / low

embedded CO2 materials such as

thermoplastics or bio-based

materials,

• Manufacturing and joining

capabilities for affordable medium-

volume lightweight EVs.

• Design capabilities for affordable

medium-volume lightweight EVs

Research Topics and results: • Conceptual lightweight design of defined modules

of an advanced electric vehicle architecture with

respect to weight and CO2 balance over life-time

• Development of highly advanced materials to a

stage that they are applicable at least in medium

volume production; considered are thermoplastic

and fibre reinforced composites, advanced hybrid

(Al/CFRP) and sandwich materials, bio-materials

• Manufacturing processes for these materials for

medium-scale production

Mission: Development of highly innovative

lightweight material technologies for

structural parts of electric vehicles

www.seam-cluster.eu & www.project-enlight.eu ENLIGHT

baseline is the

ELVA vehicle

architecture

figure © ELVA project

front module

firewall & cockpit

doors / enclosures

central floor module

subframe & suspension

Coordinator: Volkswagen AG Total costs: 13,08M€ EC contribution: 7,57M€ Start date: 1/10/2012 Duration: 48 months

Focus: • Biw with integrated battery

housing: approx. 45%

(i.e. from 355 kg to 200 kg)

• Chassis: approx. 25% (i.e. from

260 kg to 200 kg)

• Hang-on parts: at least 25% (i.e.

from 100 kg to 75 kg)

• Interior components: in the range

of 30% (i.e. from 100 kg to 70 kg)

Research Topics and results: • Development of advanced design and simulation

capabilities for multi-material vehicle concepts

• Generate a data-rich novel fast and reliable LCA

simulation tool

• Generate advancements in joining technologies

aimed at realistic industrial solutions that can

reliably and economically join a variety of

materials

• Build a set of demonstrators for destructive and

non-destructive testing and validation of

simulation results

http://eeepro.shef.ac.uk/wide-mob/index.html

Mission: Achieve a significant reduction in weight

of electric cars destined for mass-

production with minimal additional costs

ALIVE

Coordinator: Fiat Research Center

Total budget: 3,9M€

EC contribution: 2,6M€

Start date: 1/12/2010

Duration: 36 months

Research Topics and results:

• Exceptional crashworthy performance for such

small vehicle demonstrated

• Improved aerodynamics

• Embedded solar panels distributed on both

horizontal and vertical surfaces with adaptive

electronics ensuring ~20 km/d free

• Modular and reconfigurable design addressing

the WIDEst needs with ergonomic on board

space

• Distributed fail safe propulsion (before Tesla)

with symmetric powered axles

http://eeepro.shef.ac.uk/wide-mob/index.html

Focus: • Development of state-of-the-art

building blocks critical systems

• Demonstrate and validate the

integration of the developed

systems into a next generation low

weight and safe Electrical Vehicles

for urban mobility

Mission: Building blocks concepts for efficient

and safe multiuse urban electrical

vehicles

WIDE-MOB

http://eepro.shef.ac.uk/wide-mob/index.html

Mission: Fully carbon composite trailer

Conclusions: high raw material cost

high tooling cost or only simple shapes

long cycle time

high energy usage in production

availability of compatible structural adhesives

availability of in-mould paints or gel coats.

CLEANMOULD

EGV

I Ro

adm

ap

Affordable weight reduction of high-volume vehicles and

components taking into account the entire life-cycle (1)

Challenge

• Identify solutions for the significant weight reduction of vehicles, and in

particular electrified cars, which are cost-effective and viable with

respect to the intended production volumes

Scope

• A holistic, integrated and cost-driven approach should be pursued in

order to optimize the use of lightweight materials solutions in all vehicle

structures, subsystems and components (with the exception of concepts

for stand-alone powertrains), considering the entire value chain from a

life-cycle perspective: materials, tools, design, manufacturing process,

assembly and end-of-life.

Topic NMBP-08-2016 (RIA)

Affordable weight reduction of high-volume vehicles and

components taking into account the entire life-cycle (2)

Expected impact

• 10 % reduction in energy consumption of vehicle due to weight reduction

(with corresponding impact in terms of CO2 emissions

• Cost-effective weight savings depending on intended

production volumes, e.g.:

- For 50000 units per annum: at least 6 €/kg-saved;

- For 100000+ units per annum: at least 3 €/kg-saved;

• At least 6% improvement in LCA environmental impact ("from cradle to

grave") in terms of GWP (Global Warming Potential).

Implementation starts at TRL 4 and targets TRL 6

Estimated EC contrib. per proposal: EUR 5-8 Mio

Topic NMBP-08-2016 (RIA)