Lightweight Electric/Hybrid Vehicle Design

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198 Lightweight Electric/Hybrid Vehicle Design 6. Lovins and Barnett, Supercars: the coming light-vehicle revolution, Rocky Mountain Institute, Summer Study, European Council for an energy-efficient economy, Denmark, 1993 Further reading Houldcroft, P., Which Process?, Abington, 1990 Gibson/Smith, Basic welding, Macmillan, 1993 Pitchford, N., Adhesive bonding for aluminium structured vehicles, IMechE seminar, Materials – fabricating a novel approach, 1993 McGregor et al., The development of a joint design approach for aluminium automotive structures, SAE paper 922112, 1992 Pearson, I., Adding welded/mechanical fastening to adhesive-bonded joints, Automotive Engineer, Aug./Sept. 1995 Timings, R., Manufacturing technology, Longmans, 1993 Structural Adhesives in engineering, IMechE conference report 6, 1986 James, P., Isostatic pressing technology, Applied Science Publishers, 1983 Schonberger, R., World class manufacturing casebook, Collier Macmillan Institute of Materials conference, Moving forward with steel automobiles, 1993 Mann, R., Automotive plastics and composites, Elsevier Advanced Technology West, G.H., Manufacturing in plastics, PRI Goldbach, H., IBCAM Boditek conference, 1991 Hartley, J., The materials revolution in the motor industry, Economist Intelligence Unit, 1993 Young and Shane (eds), Materials and processes, Marcel Dekker, 1985 Gutman, H., New concept bumper in plastic, SITEV conference, 1990 Thermoplastic matrix composites, Profile series, Materials Information Service, DTI Wood, R., Automotive engineering plastics, Pentech Press, 1991 Design in composite materials, IMechE conference report 2, 1989 Maxwell, J., Plastics in the automobile, Woodhead Publishing, 1994 Data for design in Propathene polyurethane, Tech Service Note PP110, ICI Ashley, C., Weight saving in steel body structures, Automotive Engineer, December 1995 British Standard 8118. 1991: Structural Use of Aluminium, Parts 1 and 2 Vaschetto et al., A significant weight saving application of magnesium to car body design, paper SIA9506B02, EAEC congress, 1995 Engineering steels, Profile series, Materials Information Service, DTI Nardini and Seeds, Structural design considerations for bonded aluminium structured vehicles, SAE paper 890716/7 Ruden et al., Design and development of a magnesium/aluminium door frame, SAE paper 930413 User manual for 3CR12 steel, Cromweld Steels Cowie, G., The AISI automotive steel design manual, SAE paper 870462
Design for optimum body-structural and running-gear performance efficiency 199 8 Design for optimum body-structural and running-gear performance efficiency 8.1 Introduction Both structural and performance efficiencies are considered, in turn, within this chapter which examines first the body-structural shell and second the running gear of the vehicle. The approach to designing for lightweight, recommended in the introductory chapter, is implicit in the design calculation formulae provided for the several aspects of structural design. Second, the optimization of running gear is based on the most efficient exploitation of the special features of electric and hybrid-drive vehicles in again applying calculation techniques for accelerative performance and weight distribution; ride and handling evaluation; electric steering and braking; also CVT and drivetrain for parallel hybrid-drive vehicles. Again a fuller account of vehicle structural design can be obtained from the author’s work*, referenced at this point in Chapter 7, together with a parallel work on running gear design, applying to a wider range of vehicles. Structural design for optimum efficiency involves the best utilization of the body shell in reacting to passenger, cargo and road load inputs with minimum weight penalty. The evolving design packages for electric vehicles, described in Chapters 5 and 6, suggest that (with the possible exception of the parallel hybrid drive) layout of the electromechanical systems is not constrained by the mechanical drive from power unit to drive wheels and, particularly in the case of battery-electric vehicles, the principal mass can be spread uniformly over a wide platform area between the steered and driven wheels. This chapter examines the monocoque tubular shell and open-integral punt structure as possible structural solutions to two different EV requirements. In approaching EV structural design, an interesting departure would be for automotive body engineers to put themselves in the shoes of aerospace fuselage designers in trying to elevate the status of structural efficiency above those of passenger convenience and use of existing production equipment, both of which are important in conventional road-vehicle design. A brainstorming approach which does not rule out any possible solution would be in order for the conceptual designer of an electric vehicle. How can efficient thin-walled tubular structures be exploited? How can occupant access solutions be devised that will minimize reductions to the structural integrity of the vehicle? How can ultra-lightweight combinations of metal and polymer-composite materials be exploited in the construction? Could sandwich construction be used to obtain a load-bearing skin without need for supporting pillars and rails? These are the sorts of questions that might be asked at the concept stage of the body structure.
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100 Lightweight Electric/Hybrid Veh
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PART TWO Battery/fuel-cell EV desig
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5 Battery/fuel-cell EV design packa
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(a) cell voltage 2,5 V 2,0 1,5 1,0
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700 600 500 400 CurrentmA 300 (a) 2
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Battery/fuel-cell EV design package
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Intake filter Intercooler High spee
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Fig. 5.22 Bradshaw Envirovan. Batte
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6.1 Introduction 6 Hybrid vehicle d
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TRAVEL ELECTRIFIED, % 80 70 60 STRA
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Page 197 and 198: Hybrid vehicle design 169 The view
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