Automotive Workshop on BiW-Structures

Body Engineering Trends – The FP7 SEAM Cluster

Mondragon, 11 July 2013

Thilo Bein
Fraunhofer LBF

Bein / Mondragon Automotive Workshop © SEAM 2012 Slide No. 1

Outline

 Preface
 Lightweight design for mobility
 The SEAM cluster
 Future mobility
 Summary

Bein / Mondragon Automotive Workshop © SEAM 2012 Slide No. 2

Preface

 In the year 2050 more than 9 bn. humans will live on earth. (UN)

 In the next 30 years 450 mill. Chinese people will live in cities,
which are not existing, yet. (Lutz Engelke, Trias Projektgesellschaft mbH, auto motor sport-Kongress 2010)

 Up to the year 2030 appr. 500 cities will exist with a population over a
million citizens. 27 of them will be megacities.
(8th world congress of network Metropolis - World Ass. of Major Metropolises)

 Increasing demand on urban mobility

… with zero-emission
ideally www.cai.blogware.com [www.wienweb.at]

Bein / Mondragon Automotive Workshop © SEAM 2012 Slide No. 3

Outline

 Preface
 Lightweight design for mobility
 The SEAM cluster
 Future mobility
 Summary

Bein / Mondragon Automotive Workshop © SEAM 2012 Slide No. 4

Challenges for Future Mobility
Reduced emissions C0
CO22emission
Emissionsdevelopment
Development
US Tier2 EU 5 Sept- Phase II National Phase III EU6
in g
Bin5 2009 Jan-2010 Jan-2010 Jan-2013 Sept-2014 CO2/km
Exhaust gas emissions

PM
NOX § CO

HC
160

2006
130 95

2020
70
2012 2025

Price / availability
Limited Fuel of oil Increasing traffic
(passenger and transport)

Until 2030 in the

transport sector, the
predicted increase of fuel
demand totals 55 %
www.in-brasilien.de Bild: AP

 We have to reduce weight of all kind of vehicles

[Source: Grotendorst, Continental, 2009]
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Life cycle fuel efficiency improvement by lightweight
4,000,000 km

1,000,000 km

200,000 km

Vehicle []
Data from: Helms, LCA case studies – 2006
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Global fuel savings by lightweighting

Data from: Helms, LCA case studies – 2006

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Contribution of vehicle systems to total weight

 Body & chassis/suspension components are

loaded by fluctuating forces
 Significant improvement on material & mass
efficiency can be generated only by managing
the stress vs. strength interference
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Challenges and strategies of lightweight design

Source: M.Goede, VW Group Research

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Material mix/technology to lower vehicle weight

 Steel intensive vehicle

structure is cost effective
 Aluminum and composites
become more often used
 Vehicle life cycle and end-
of-life-vehicle have to be
considered

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Trend towards multi-material design

Source: M.Goede, VW Group Research, SLC

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But … GHG emission must be considered of complete life-time

Source: M.Goede, S. Krinke, VW Group Research

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CO2-profiles in the production phase

Source: M.Goede, S. Krinke, VW Group Research

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Lightweight design throughout the life-cycle

Source: M.Goede, S. Krinke, VW Group Research

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Additional manufacturing costs

Source: Fine, Roth, MIT MSL, MIT Manufacturing Round Table, 2010
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Weight saving considering secondary savings

Source: Fine, Roth, MIT MSL, MIT Manufacturing Round Table, 2010
Bein / Mondragon Automotive Workshop © SEAM 2012 Slide No. 16
Outline

 Preface
 Lightweight design for mobility
 The SEAM cluster
 Future mobility
 Summary

Bein / Mondragon Automotive Workshop © SEAM 2012 Slide No. 17

Lightweight as development target

 to meet the CO2 targets

of ICE-driven cars
(-100 kg = 8.5 gCO2/km)

 to compensate for the

-10% mass of the battery

 to reduce the mass of

the battery

Mass reduction: > 250 kg  to extend the range of

HEV/FEV
Base data: Affenzeller, AVL Vehicle mass [kg]

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Main Challenges: Driving Range and Battery Costs

80 % of all
25-
customers drive
20- less than 50 km
% of customers

per day
15-

10-

5-

0- km
0-1 2-4 5-10 11-20 21-50 51-100 >100

 Besides battery technologies, light weight is the key

[Data: Corsini, GM Europe, 2009]

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Mass vs. energy for zero-emission vehicles

10 kWh

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Approach
Two different proposals were initiated , each addressing the
complete vehicle (BiW, hang-on parts, chassis (suspension) and
interior) but
 ALIVE addressing matured technologies focusing on their deployment
in vehicle structures,
 ENLIGHT addressing highly innovative materials.
 Differentiation is done by type of materials considered
 both projects are based on vehicle architecture currently being
considered in ELVA and e-LIGHT
 target vehicle is a 2-4 passenger car for mass production
 weight reduction will be assessed against energy and CO2-reduction
 ALIVE will be the benchmark for solutions developed in ENLIGHT

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Correlation between ALIVE and ENLIGHT

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ENLIGHT/ALIVE display production volume correlation

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 Advanced high volume affordable Enhanced lightweight design by
lightweighting for future advanced lightweight materials
electric vehicles

Coordinator: VW Liaison Team Coordinator: Fraunhofer LBF

C.R.F, VW, fka,
ViF, LBF,
B&W

Modeling and testing for improved

safety of key composite structures in Safe small electric vehicles through
alternatively powered vehicles advanced simulation methodologies

Coordinator: fka Coordinator: ViF

 Biggest European RTD-Cluster on lightweight design Contact:

Prof. Dr.-Ing. Thilo Bein
 47 partner from 11 countries, about 19 Mio. € funding E-Mail: [email protected]
 joint dissemination activities between the SEAM projects Web: www.seam-cluster.eu
 The two new projects EPSILON & URBAN-EV will join
as associated partners in September 2013
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Bein / Mondragon Automotive Workshop © SEAM 2012 Slide No. 25
All 4 SEAM projects are linked and have ties to several European
projects

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The ALIVE Project - Motivation

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The ALIVE Project - Objectives

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The ALIVE Project – Weight Targets

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The ALIVE Project – Key Deliverables

 Design capabilities and innovative structural layouts for affrodable high

volume lightweight EV
 Materials and manufacturing capabilities for affordable high volume
lightweight EV
 Experimental and simulation validation environments to allow for quick
& reliable multi-parameter design & optimisation loops
 Demonstration of the abovementionend results into a full scale
demonstrator vehicle covering BiW, hang-on parts, chassis and heavy
interiors, including battery pack integration, innovative safety
mechanism and several new materials and manufacturing technologies

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The ENLIGHT Project – 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
 Demonstration of the proposed solutions through the realization of at
least 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
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The ENLIGHT Project – Weight targets

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The ENLIGHT Project – Key deliverables
 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 ©*SEAM 2012
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The MATISSE Project – Objectives

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The SafeEV Project – Objectives

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The SEAM cluster facilitates interaction between the 4
projects

 Coordinating meetings between projects

 Follow up common GANTT chart, deliverables exchanges
 Preparing / organising the Liaison Group telcons and meetings
 Coordination of common dissemination / exploitation activities
 final exhibitions, workshops, conferences, and training courses
 Establishing web-pages, email newsletter, and leaflet
 Communication of relevant events / information to partners
 Providing best practices for exploitation activities and coordinating them

Bein / Mondragon Automotive Workshop © SEAM 2012 Slide No. 36

Outline

 Preface
 Lightweight design for mobility
 The SEAM cluster
 Future mobility
 Summary

Bein / Mondragon Automotive Workshop © SEAM 2012 Slide No. 37

Shaping future mobility

 Sustainable vehicle
technology moves to
electric drives
 Conversion design
provides chance to
market products
initially
 Performance, weight
and costs of battery
systems are an open
issue
 New vehicle concepts
have to „re-invent“ the
structure of a passenger
car
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Future concepts for zero-emission vehicles

 Integration of wheel + drive

 Centralized/de-centralized energy storages
 Active and passive assistant systems
 How-to-drive (speed, distance etc.)
 Where-to-drive (route, traffic jam, parking etc.)
 Reduction of resistance
 Aerodynamics
 Lightweight structures + optimized tire/wheel systems

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New driveline concepts for small urban vehicles

 Flexibility with regard to design

and package
 »Torque vectoring« and all-
wheel traction
 Co-operative braking

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Summary

Population and economic growth create a huge demand for

transportation
Energy is »driving« transportation engineering – searching for more
sustainable and efficient concepts related to transport & vehicles
Lightweight helps to improve energy efficiency especially for passenger
cars and trucks
Materials and manufacturing are enablers to come up with the most
cost efficient and robust lightweight solutions
Lightweight design needs sophisticated methods for data acquisition, data
processing, material characterization & fatigue testing, as well as
design & development

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