Fachhochschule Aachen
Fachbereich Luft- und Raumfahrttechnik
A design approach for lightweight construction of a car body with an example on the micro-car “ec2go”
Lehr- und Forschungsgebiet Karosserietechnik
M.Sc. Anuja Nagle / FH Aachen
Prof. Dr.-Ing. T. Roeth / Imperia GmbH
6th European Altair Technology Conference23rd und 24th April 2013 | Turin, Italy
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 23. April 2013 | 2
Contents
A design approach for lightweight construction of a car body with an example on the micro-car “ec2go”
� Introduction
� Micro-Car ec2go
� Flexbody Concept
� Intelligent Car Body (ICB) Approach
� Development of Structural Knowledgebase
� Outlook
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 23. April 2013 | 3
Contents
� Introduction
� Micro-Car ec2go
� Flexbody Concept
� Intelligent Car Body (ICB) Approach
� Development of Structural Knowledgebase
� Outlook
A design approach for lightweight construction of a car body with an example on the micro-car “ec2go”
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 23. April 2013 | 4
Motivation
Importance of small sized vehicle batch production
� High demands for vehicle derivatives
� Green energy � Increasing need for vehicles with
alternate drives eg. Electric vehicles
Challenges of small series vehicle production
� Restricted knowledge for design
� High development time
� High development costs
� High capital investment
� Fast launching in market
ICB
A design approach for lightweight construction of a car body with an example on the micro-car “ec2go”
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 23. April 2013 | 5
Partners
Research Partners
Industry Partners
Research Partners
Industry Partners
FB Luft- und RaumfahrttecnikFB EnergietechnikFB GestaltungFB Elektrotechnik und
InformationstechnikFB Maschinenbau und
MechatronikSIJ Solar-Institut Jülich
Supported by
A design approach for lightweight construction of a car body with an example on the micro-car “ec2go”
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 23. April 2013 | 6
Contents
� Introduction
� Micro-Car ec2go
� Flexbody Concept
� Intelligent Car Body (ICB) Approach
� Development of Structural Knowledgebase
� Outlook
A design approach for lightweight construction of a car body with an example on the micro-car “ec2go”
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 23. April 2013 | 7
The Micro-Car ec2go
� Developed as an integral part of a mobility concept
� 2,5m (smaller than Smart)!
� Offers place for 3 people (1+2-Seater)
� Transperent panorama view
� Cross parking possilble
A design approach for lightweight construction of a car body with an example on the micro-car “ec2go”
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 23. April 2013 | 8
Contents
� Introduction
� Micro-Car ec2go
� Flexbody Concept
� Intelligent Car Body (ICB) Approach
� Development of Structural Knowledgebase
� Outlook
A design approach for lightweight construction of a car body with an example on the micro-car “ec2go”
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 23. April 2013 | 9
Flexbody Construction Concept
Geom
etr
yM
anufa
ctu
ring
Str
uctu
re
Knowledgebase
Topology
Profiles
Joints
Car body structure
urb-e (Source: Imperia GmbH)
Lampo3 (Source: ProtoScar)
A design approach for lightweight construction of a car body with an example on the micro-car “ec2go”
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 23. April 2013 | 10
Flexbody Material Concept
� Combination of different materials possible
� Selection of materials to achieve high level of structural performance andlight weight design
„Das richtige Material an der richtigen Stelle!“
A design approach for lightweight construction of a car body with an example on the micro-car “ec2go”
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 23. April 2013 | 11
Contents
� Introduction
� Micro-Car ec2go
� Flexbody Concept
� Intelligent Car Body (ICB) Approach
� Development of Structural Knowledgebase
� Outlook
A design approach for lightweight construction of a car body with an example on the micro-car “ec2go”
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 23. April 2013 | 12
Manufacturing Intelligence
Intelligent Car Body (ICB) Approach
Virtual ValidationVirtual Validation
Lampo3
Source: Protoscar / TK-SE / Imperia GmbH
ec2go e-car-sharing
Source: FH Aachen
Vehicle Base InformationVehicle Base Information
Attribute ConfiguratorAttribute Configurator
Topology ConfiguratorTopology Configurator
Section ConfiguratorSection Configurator
Joint ConfiguratorJoint Configurator
ConventionalCAE Methods
Geometrical Intelligence Structural Intelligence
Deformation ConfiguratorDeformation Configurator
Level of“I
nte
llig
ence”
A design approach for lightweight construction of a car body with an example on the micro-car “ec2go”
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 23. April 2013 | 13
Fields of Intelligence in ICB
For parametric CAD construction
Ste
p1:
Topolo
gy
Ste
p2:
Pro
file
sSte
p3:
Join
ts
For selection of materials and manufacturing processes
For optimum design of profile cross sections
Semi-empirical evaluation
Load
dis
trib
ution
Pro
file
sele
ction
Pro
file
D
ata
base
Join
t D
ata
base
Geometrical Intelligence Manufacturing Intelligence Structural Intelligence
A design approach for lightweight construction of a car body with an example on the micro-car “ec2go”
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 23. April 2013 | 14
Contents
� Introduction
� Micro-Car ec2go
� Flexbody Concept
� Intelligent Car Body (ICB) Approach
� Development of Structural Knowledgebase
� Outlook
A design approach for lightweight construction of a car body with an example on the micro-car “ec2go”
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 23. April 2013 | 15
a. Attribute Configurator
Tasks
� Define a safety model for target vehicle
� Define structural performance targets for whole vehicle and car body for
different crash scenarios
− Overall deformation behavior of vehicle
− Trends of force – deformation curves
− Energy of deformation
− Distribution of deformation energy into car body and other parts
A design approach for lightweight construction of a car body with an example on the micro-car “ec2go”
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 23. April 2013 | 16
- FMVSS208, 0º, 100%, 56 km/h- FMVSS208, 30º, 100%, 56 km/h- ECER94, 0º, 40%, 56 km/h- Euro NCAP, 0º, 40%, 64 km/h- ECER12, 0º, 100%, 53 km/h- Frontal Pole Crash, 30 km/h
Level 0Level 1Level 2
- ECER95, 90º, 50 km/h- Euro NCAP, 90º, 50 km/h- IIHS, 50 km/h- Euro NCAP – Pole, 90º- FMVSS 214 NPRM, 75º- FMVSS 214, static, 90º
Side crash
- ECER34, 0º, 100%, 38 km/h- IIHS, 16 km/h- FMVSS301, 80 km/h- TRIAS 33, 50 km/h
Rear crash
- FMVSS216 – Roof crush- ATZ Bumper Test- ECE-R42 Bumper Test- Pedestrian Safety
General crash tests
Frontal crash
Example: Safety Model for ec2go
a. Attribute Configurator
A design approach for lightweight construction of a car body with an example on the micro-car “ec2go”
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 23. April 2013 | 17
…
…
Deformation energy
Energy distribution
Car body Other parts
75 - 80% 20 - 25%
Frontal crash
Example for frontal crash against rigid wall
Know
ledgebase
usin
g C
AE
sim
ula
tions
Application o
f know
ledgebase
for
ec2go
Example: Definition of Targets for ec2go
a. Attribute Configurator
A design approach for lightweight construction of a car body with an example on the micro-car “ec2go”
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 23. April 2013 | 18
b. Deformation Configurator
Tasks
� Defining deformation modes for each component of car body
� Defining performance targets for each component
Axial folding
CrumplingMixture of foldingand bending
Bending
Source: ec2go, FH Aachen
…
Modes of deformation observed in “Flexbody” profiles
Basic deformation modes �Simple loads
Axial failure
Bending failure
Reducedto
Reducedto
A design approach for lightweight construction of a car body with an example on the micro-car “ec2go”
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 23. April 2013 | 19
c. Section Configurator
Tasks
� Develop relatively simple methods for predicting component performance
� Evaluate and choose component design configuration to match pre-
defined performance targets
Parameter 1
Param
eter 2
Semi-empiricalevaluation methods
for predictingcomponent
performance
In a defined design space for component
cross sections
Using tests and CAE simulations
A design approach for lightweight construction of a car body with an example on the micro-car“ec2go”
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 23. April 2013 | 20
Contents
� Introduction
� Micro-Car ec2go
� Flexbody Concept
� Intelligent Car Body (ICB) Approach
� Development of Structural Knowledgebase
� Outlook
A design approach for lightweight construction of a car body with an example on the micro-car “ec2go”
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 23. April 2013 | 21
Outlook
� Potentials of the FlexBody construction concept are demonstrated through
the Micro-Car ec2go.
� Knowledgebase developed under the ICB approach is applied and
validated using the ec2go car body.
Source: Imperia GmbH
A design approach for lightweight construction of a car body with an example on the micro-car “ec2go”
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 23. April 2013 | 22
Contact
Thank you for your attention!
Prof. Dr.-Ing. T. RoethImperia GmbHSoerser Weg 9D-52062 AachenTel.: +49 (0)241 608 33 [email protected]
M.Sc. A. Nagle“Automotive Body Engineering”University of Applied Science AachenBoxgraben 98-10052064 AachenTel.: 0241/6009-52934E-Mail: [email protected]
A design approach for lightweight construction of a car body with an example on the micro-car “ec2go”
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 23. April 2013 | 23
Front crash with rigid wall
Load distribution Acceleration pulse
A design approach for lightweight construction of a car body with an example on the micro-car “ec2go”
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