Lightweight Electric/Hybrid Vehicle Design

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246 Lightweight Electric/Hybrid Vehicle Design Some researchers suggest that rolling resistance data for very small tyres, as may be used in lightweight urban electric cars, is not readily available from manufacturers. Work done by Margetts 14 using a towed vehicle fitted with test tyres, and load-cell towbar, has shown results as at (a) in Fig. 8.25 for such tyres. The results show a different relationship to that obtained by the classic formula due to Hoerner (dotted curve) for conventional-sized tyres. Michelin’s lower rolling-resistance ‘Energy’ tyres are said to compensate for the loss of wetgrip in moving to lower hysteresis tread compounds, for reducing drag, by new rubber formulations, carcass construction and tread patterns. By obtaining low hysteresis values at low frequency vibration, and the converse at high frequencies, the company have effectively reduced rolling resistance by 20% over conventional radial-ply construction, (b). Recently the company extended this technology to launch tyres particularly designed for electric-vehicle application, to obtain 35% rolling-resistance reduction against conventional tyres. The Proxima brand is designed for urban traffic conditions and claims unusually good grip on polished surfaces often encountered in city centres using a tread pattern with a high number of block edges. Fine cuts made in the centre of the tread blocks also help to achieve silent running, coupled with the plugging of tread drainage channels at their outer edges. (a) Coefficient of rolling resistance(CR) .04 .03 .02 .01 Target Knorez and Shelukin (CV on real road) Anderson (truck at 48 km/h) Hoerner Stieler (truck at 80 km/h) .0 0 300 600 900 Pressure (kN/m 2 ) } Go kart ‘rain’ 2.50 x 8 2 ply 4 x 8 tubeless 4 ply 4 x 8 5.20 SR 10 (A) tubeless 5.20 SR 10 (B) tubeless Energy consumed per volume units Fig. 8.25 Rolling resistance for small-wheeled and specialist tyres: (a) small tyres; (b) Michelin Energy tyres. 1 Margetts on real road (1.6km/h) Rolling resistance frequency domain 1000 Deformation frequency High compund Energy tyre compound Low compund Adherence frequency domain 1 000 000 (b)
Design for optimum body-structural and running-gear performance efficiency 247 References *Fenton, J., Handbook of automotive body and systems design, Professional Engineering Publishing, 1999 **Fenton, J., Handbook of automotive powertrain and chassis design, Professional Engineering Publishing, 1999 1. Beerman, H., The analysis of commercial vehicle structures, Mechanical Engineering Publications, 1989 2. Peery, D., Aircraft structures, New York, McGraw-Hill, 1950, 566 pp. 3. Tidbury, G., Stress analysis of vehicle structures, ASAE Note 1, College of Aeronautics, Cranfield, 1965 4. Fenton, J., Shell beams and the Argyris method, Automotive Design Engineering, March 1963 5. Pawlowski, J., Vehicle Body engineering, Business Books, 1969 6. Analytical method for chassisless vehicle design, Automobile Engineer, 1953, vol. 43, pp. 103–111; Structural design Part 2: The front end structure, Automobile Engineer, 1953, vol. 43, pp. 152–157. 7. Tae-Un et al., Structural design of aluminium space frame with battery tray, SAE paper 960524 8. Lilley and Mani, Roof crush strength improvement using rigid polyurethane foam, SAE paper 960435 9. Taborek, Mechanics of vehicles, Machine Design, Penton, May to December 1957 10. Autotech paper C498/35/052, 1995 11. Rocard, Y., L’instabilite en Mechanique, Masson et Cie, Paris, 1954 12. Howell, Crosswind response of cars, Proc. SITEV, 1988 13. Svenson, The working stresses of wheel rims, ATZ, No. 8, 1967 14. Margetts, E., Influence of rolling resistance on very light cars, Automotive Design Engineering, April/May 1981 Further reading Fenton, J., Handbook of automotive body construction and design analysis, PEP, 1998 Donald, I. (ed.), Thin-walled structures, Elsevier, 1990 Timoshenko and MacCulloch, Elements of strength of materials, Van Nostrand Ali et al., The application of finite element techniques to the analysis of an automobile structure, Proc IMechE, 1970–71 Fagan, M., Finite element analysis, Longman, 1992 Argyris and Kelsey, Energy theorems and structural analysis, Butterworth Amos, R., Structural design analysis of commercial vehicle cabs, IMechE conference paper C134, 1984 Curle and Watson, Structural analysis, body design and development, IBCAM Boditek conference, 1985 Guignard, J., Human response to intense low-frequency noise and vibration, Proc. I. Mech. E., Vol. 182, Part 1, No. 3, 1967/8 Gibbs and Richards, Stress, vibration and noise analysis in vehicles, Applied Science Publishers, 1975 Brughmans et al., The application of FEM-EMA correlation and validation techniques on a bodyin-white, paper 3 in IMechE Vehicle NVH and refinement conference report C487, 1994 Burton and Southall, Noise, vibration and harshness in the automotive industry, paper 3, session 3R, Design Engineering Show conference, 1982
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iv Contents Butterworth-Heinemann L
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vi Contents 4.5 Process engineering
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viii Preface natural gas, which is
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x About Prefacethe authors working
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xii Lightweight Electric/Hybrid Veh
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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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Varta Electric Power: Nickel-metal-
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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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6.2 Hybrid-drive prospects Hybrid v
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TRAVEL ELECTRIFIED, % 80 70 60 STRA
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Hybrid vehicle design 147 750 kg to
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M [Nm] 500 450 400 350 300 250 200
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6.3.6 TAXI HYBRID DRIVE Hybrid vehi
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Hybrid vehicle design 153 The Rover
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Hybrid vehicle design 155 as a star
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Hybrid vehicle design 157 injection
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Hybrid vehicle design 159 In ‘sta
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Hybrid vehicle design 161 power and
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Hybrid vehicle design 163 The batte
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Hybrid vehicle design 165 into mech
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Hybrid vehicle design 167 drive ele
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Hybrid vehicle design 169 The view
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Hybrid vehicle design 171 6.5.4 ADV
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Lightweight construction materials
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(a) (d) (e) Lightweight constructio
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4.2 4.2 5.6 4.2 7.0 5.6 4.2 5.6 5.6
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(a) Creepstrain dE/dt (b) 3.0 2.0 1
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