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© ENLIGHT 2012 Slide No. 1Name / Event
The ENLIGHT Project
Enhanced Lightweight DesignSCP2-GA-2012-314567
Introduction of project rationale, approach and scope
© ENLIGHT 2012 Slide No. 2Name / Event
General Information
Project full title: Enhanced Lightweight Design (ENLIGHT)
THEME [GC.NMP.2012-2 GC.NMP.2012-2]
[Innovative advanced lightweight materials for the next generation of environmentally-friendly electric vehicles], Grant Agreement No. 314567
Coordinator: Fraunhofer LBF, Thilo Bein
Start Date of contract: 01/10/2012
Duration: 48 months
Total Budget: 10,9 MEUR
Funding: 7,1 MEUR
© ENLIGHT 2012 Slide No. 3Name / Event
Partners
CRF Magneti Marelli Università degli Studi di Firenze
Fraunhofer LBF Volkswagen Benteler ika PE International Tecnaro
D
Renault
F
KU Leuven
B
Bax & Willens Sistemas y Procesos Avanzados
E I
Volvo Oxeon Swerea SICOMP
S
AIT
A
P
IDMEC
DSM Airborne
NL
GB
Jaguar Land Rover University of Warwick
© ENLIGHT 2012 Slide No. 4Name / Event
Motivation
-10%
Mass reduction: > 250 kg
Base data: Affenzeller, AVL Vehicle mass [kg]
to meet the CO2 targets of ICE-driven cars(-100 kg = 8.5 gCO2/km)
to compensate for themass of the battery
to reduce the mass ofthe battery
to extend the range ofHEV/FEV
…but with same safety and comfort
Lightweight as development target
© ENLIGHT 2012 Slide No. 5Name / Event
Motivation - Mass vs. energy for zero-emission vehicles
10 kWh
© ENLIGHT 2012 Slide No. 6Name / Event
Motivation - Trend towards multi-material design
Source: M.Goede, VW Group Research, SLC
© ENLIGHT 2012 Slide No. 7Name / Event
ConceptELVA
Concept of light BiW for EV´s
Space frame design
Modularity in battery and BiW
design
SuperLIGHT-Car Economic demonstration of
multimaterial vehicle structuresfor high-volume producedcombustion cars
Source: Fraunhofer LBF, „SmartBatt“ project“ Source: „ELVA“ project, 2013
Source: „SuperLIGHT-Car“ project, 2009
SmartBatt
Fully integrated battery housing
Lightweight battery concept
New materials for battery
systems
MATISSE Modeling and testing
Safety of composite structures
SafeEV Modeling and testing of small EVs
Safety of vulnerable road users
ALIVE High volume
Low weight
Low costsSource: M. Kurz , Volkswagen Group Research, K-EFFG/L, 2013
ENLIGHT medium volume
Novel materials
Low weight
© ENLIGHT 2012 Slide No. 8Name / Event
Objectives
Development of highly innovative lightweight / low embedded CO2 materials for their application in medium-volume automotive production (50.000 units/year)
Design capabilities for affordable medium-volume lightweight EVs
Manufacturing and joining capabilities for affordable medium-volume lightweight EVs
Experimental and simulation validation environments to enable rapid & reliable multi-parameter optimisation loops when designing with these new materials
LCA and economic analysis to ensure the highest probability of application by 2020, taking into account all salient factors
Demonstration of the proposed solutions through the realization of 5 full scale demonstrator modules, covering different distinguishing features of purpose-designed EVs:
Front module, Firewall, Central floor section, Sub-frame & suspension, and Doors / enclosures
© ENLIGHT 2012 Slide No. 9Name / Event
Weight Targets
ModuleBenchmark
EV (Nissan Leaf)
SLC impact ALIVE ENLIGHT
% reduction
over ALIVE
% reduction over SLC
% reduction over
benchmark EV
BiW (medium risk) 380 266 215-230 172-184 -20.0% -33.8% -53.7%
BiW (high risk) 380 266 200 160 -20.0% -39.9% -57.9%
Chassis 270 270 200 160 -20.0% -44.0% -44.0%
Heavy interior 100 100 70 56 -20.0% -40.0% -40.0%
Hang-on parts 100 100 75 60 -20.0% -40.7% -40.7%
Overall (best case) 850 736 545 436 -20.0% -40.8% -48.7%
Overall (worst case) 850 736 575 460 -20.0% -37.5% -45.9%
© ENLIGHT 2012 Slide No. 10Name / Event
Work Structure
LCA
&
ELV
front-enddoor-
modulesuspensionsub-frame firewall
material modeling & simulation
manufacturing
validation & demonstration
module design
material development
characterisation & testing
advanced hybrid materials
fibre-reinforced plastics
composites
renewables
centralfloor
vehicle concepts from ELVA
© ENLIGHT 2012 Slide No. 11Name / Event
WP 1 Module Design
conceptual design of selected modules
subframe & suspension
front module
firewall & cockpit
doors / enclosures
central floor module
conceptual design of selected modules front module:
increased crash performance subframe & suspension:
function integration and improved NVH door/enclosures:
function, integration, increased crash performance and improved NVH
cockpit & firewall: function integration, improved acoustics
central floor module: function integration, strength and stiffness properties
• the full vehicle is considered in a virtual design approach.
• use of highly advanced materials, fully exploiting their unique properties regarding lightweight potential (specific strength, weight or stiffness), crash and NVH behavior
© ENLIGHT 2012 Slide No. 12Name / Event
WP 2 Simulation
Material and vehicle simulation
• Development, calibration and validation ofmaterial models that allow the description ofthe material behaviour in all relevant simulationenvironments
• Validation and calibration of material modelsby mechanical testing
• Simulation and optimisation of attributes on module level
© ENLIGHT 2012 Slide No. 13Name / Event
WP 3 Material Development
allow manufacture at medium production volumes
provide affordable vehicle solutions
have added functionality and/or increased safety
Development of novel lightweight materials
© ENLIGHT 2012 Slide No. 14Name / Event
WP 4 Manufacturing
Adapted manufacturing technologies for novel lightweight materials
welded stiffeners
• development and the technological feasibility evaluation of innovative
manufacturing, welding and assembly technologies
for the multi-material concepts/modules
• resulting in a smaller number of parts within the overall vehicle architecture
• Consideration of a production volume of about 50.000 modules per year.
© ENLIGHT 2012 Slide No. 15Name / Event
WP 5 Characterisation & Testing
Testing on component and module level
• Provision of experimental data for validation of the module design and numerical models.
• Development of a characterisation and testing strategy considering accelerated testing
• These strategies will then be applied on component level and module level
© ENLIGHT 2012 Slide No. 16Name / Event
WP 6 Validation / Proof of Feasibility
• realization of the modules in hardware applying the developed ENLIGHT materials and manufacturing technologies
• proving the feasibility of applying highly advanced lightweight materials as well as the corresponding manufacturing technologies in medium volume production
• validation on module level, the realized weight saving and performance with respect to static and dynamic behavior, structural durability and NVH
• validation of the full vehicle virtual design
Validation of weight targets and manufacturing concepts
© ENLIGHT 2012 Slide No. 17Name / Event
WP 7 LCA
Life-cycle analysis and life-cycle cost assessment
• Assessment and comparison of the CO2 emissions and the mass/energy balance related to the whole life cycle of the modules
• Defining of the vehicle recyclability/recoverability
• Analysis of the advantages/drawbacks of a substitution of metallic with non-metallic materials
• Development of an economic LCA model allowing for clear economic indicators that enable the affordability versus light-weighting trade-off
© ENLIGHT 2012 Slide No. 18Name / Event
Timing10/12 2013 2014 2015 09/2016
Simulation
Material Development
Manufacturing
Characterisation & Testing
Validation & Proof of Feasibility
Life Cycle Assessment
Module Design
Dissemination & Exploitation
© ENLIGHT 2012 Slide No. 19Name / Event
Expected Results / Research performance indicators
each considered module saves 20% weight compared to the respective component of the ALIVE project
Availability and implementation of advanced lightweight materials such as hybrids, CFRPs or thermoplastics Qualification of renewables and low-cost fibres for the automotive sector meeting
current automotive standards and required manufacturing costs
New, advanced materials meet specifications regarding weight savings, crashworthiness and applicability in medium-scale production (50.000 units/year)
Elaboration of material data and models for new lightweight materials such that they can be implemented in the vehicle design
Elaboration of testing procedures for new materials, components and sub-systems Validated accelerated test methods reducing test time by half
Durability of components and sub-systems proven according automotive standards
Crashworthiness of components and sub-systems proven meeting a EuroNCAP of between 4 and 5 *
© ENLIGHT 2012 Slide No. 20Name / Event
Expected Results / Research performance indicators
Elaboration of cost-efficient joining and manufacturing technologies for new materials suitable for medium-scale production (50.000 units/year) Elaboration energy-efficient processes enabling a CO2 foot print equal or lower that of
conventional solutions made from metals
Elaboration of continuous manufacturing processes for new, advanced lightweight materials reducing cycle times by half or better
reduced manufacturing costs at least 20% lower than the SotA validated
Elaboration of function integration into lightweight modules Number of parts of a sub-system reduced such weight savings of 20% or more can be
achieved with same or higher functionality
Proof of feasibility that integration of smart function such as smart damping, active systems for NVH or monitoring leads to overall weight savings of 20%
New, advanced lightweight materials implemented in the optimal design of electric vehicles
LCA implemented as parameter in the vehicle design process
© ENLIGHT 2012 Slide No. 21Name / Event
Dissemination – The SEAM cluster
Modeling and testing for improved safety of key composite structures in
alternatively powered vehicles
Coordinator: fka
Safe small electric vehicles through advanced simulation methodologies
Coordinator: ViF
Coordinator: VW
Advanced high volume affordable lightweighting for futureelectric vehicles
Coordinator: Fraunhofer LBF
Enhanced lightweight design byadvanced lightweight materials
Biggest European RTD-cluster on lightweight design
47 partner from 10 countries, about 19 Mio. € funding
Joint dissemination activities between the SEAM projects
The two new projects EPSILON & URBAN-EV will join as associated partners in September 2013
Liaison TeamCRF, VW, fka, ViF, LBF, ika,
B&W
www.seam-cluster.eu
© ENLIGHT 2012 Slide No. 22Name / Event
Contact
Project website www.project-enlight.eu
Email [email protected]
Thilo Bein
Fraunhofer LBF
Bartningstr. 47
D-64289 Darmstadt
Phone +49 6151 705 463
Fax +49 6151 705 214
E-Mail [email protected]
Internet www.lbf.fraunhofer.de