Function-integrated Lightweight Design Structures for Next Generation Ground Vehicles , IEA Workshop

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1 Function-integrated Lightweight Design Structures for Next Generation Ground Vehicles , IEA Workshop Dipl.-Ing. Gundolf Kopp Dipl.-Ing. Andreas Höfer Dipl.-Ing. Diego Schierle Prof. Dr. -Ing. Horst E. Friedrich

2 Slide 2 DLR - German Aerospace Center DLR's mission: exploration of the Earth and the solar system research aimed at protecting the environment development of environmentally-friendly technologies to promote mobility, communication and security employee are working at 32 research institutes and facilities in 9 locations and 7 branch offices. SPACE AERONAUTICS TRANSPORT ENERGY SECURITY Source: DLR

3 Slide 3 DLR - German Aerospace Center Institute of Vehicle Concepts: 72 employee Vehicle systems and technology assessment Vehicle energy concepts Alternative energy conversion Lightweight and hybrid construction SPACE AERONAUTICS TRANSPORT ENERGY SECURITY Source: DLR

4 Slide 4 Evolution of Megacities - We are reaching the limits of oil extraction - Climate change is taking place - Growing population, concentrated in megacities Source: display/ Vehicle Concepts - Lower energy consumption - Reduced CO 2 emissions by using CNG - Reduce NOx emissions by using CNG - Zero-Emission in urban areas - Alternative and renewable energy sources - Source: DLR Source: versust.blogsport

5 Slide 5 Strategies for Lightweight Design Lightweight Specifications Lightweight Concept Lightweight Materials Lightweight Shape Alternative drive technologies offer many new opportunities for the creation of synergies and the integration of various functions leading to new components and lightweight structures

6 Slide 6 DLR Konzept Fahrwerk, Antrieb, Speicher Technologie - ConFAST (II) DLR- Wabentank Free-Shapeable-Modular High Pressure Storage (I) DLR-LEICHT Lightweight Energy-efficient Integrative Chassis with Hub-motor Technology

7 Slide 7 (I) LEICHT Concept Introduction - Wheel guidance mechanism: - Linear guidance for absorption of forces in 2 dimensions and bending moments in 3 dimensions - Camber and castor angle stability - Housing of drive: - Transmission of forces and cooling functions - Attachment to wheel guidance mechanism connection damper side damper guiding rail/ upper carriage brakeside discguiding rail shock absorbers running linear supports surface ball bearings coil springs electrical cv-joint drive with housing lower carriage roller bearings According to: Höfer, Wiesebrock, et. al. Stuttgart Symposium 2014

8 Slide 8 (I) LEICHT Demonstration of Functions - Current Design: - Integration of functions - Concept lightweight design - Shape optimisation - Future Design: - Lightweight material - Topology optimisation Torque transmission Wheel travel According to: Höfer, Wiesebrock, et. al. Stuttgart Symposium 2014

9 Slide 9 (I) LEICHT Competitive Advantages Concept with centrallypositioned-drive Concept with drive positioned close-to-the-wheels Concept with wheel-hubmotor Source: Mitsubishi i-miev Source: ZF etb Source: Fraunhofer Frecc0 DLR LEICHT Goal combining the advantages of centrallypositioned drive and hubmotor concepts According to: Höfer, Wiesebrock, et. al. Stuttgart Symposium 2014

10 Slide 10 (I) LEICHT Competitive Advantages Package proportions Based on the best available data in [Vol %] Unsprung mass proportions Based on the best available data in [kg %] LEICHT 51 l LEICHT 25 kg Benchmark 1 Benchmark 2 Benchmark 3 DLR LEICHT According to: Höfer, et. al. SAE World Congress & Exhibiltion 2014

11 Slide 11 (I) LEICHT Simulation Results - Full vehicle simulation: - Double lane change while cornering - Excellent behaviour of innovative suspension confirmed - Torque vectoring to improve stability and performance According to: Höfer, Wiesebrock, et. al. Stuttgart Symposium 2014 According to: Höfer, Wiesebrock, et. al. Stuttgart Symposium 2014

12 Slide 12 DLR Konzept Fahrwerk, Antrieb, Speicher Technologie - ConFAST (II) DLR- Wabentank Free-Shapeable-Modular High Pressure Storage (I) DLR-LEICHT Lightweight Energy-efficient Integrative Chassis with Hub-motor Technology

13 Slide 13 (II) DLR- Wabentank Free-Shapeable-Modular High Pressure Storage - Motivation: - Reduction of emissions - CNG / H 2 as alternative fuels - State of the Art: - Stored in cylindrical vessels - Range approx. 400km - A need to improve range - To Do: - Increase the available volume - Increase the design variability

14 Slide 14 (II) DLR- Wabentank Wide range of packaging variations as enabler - State of the Art: Innovation through lightweight material - Basic Concept DLR Patent Innovation through design - Variability in the use of the available space

15 Slide 15 (II) New Production Approach Type 3 Modular and Fully Scalable High Pressure Storage According to: Schierle, Friedrich FKFS-8. Tagung Gasfahrzeuge 2013

16 Slide 16 (II) New Production Approach Type 3 Modular and Fully Scalable High Pressure Storage Aluminium production Welding each cell Winding each cell Assembly 3D-Winding According to: Schierle, Friedrich FKFS-8. Tagung Gasfahrzeuge 2013

17 Slide 17 (II) DLR- Wabentank Potentials - By changing the winding composition it is possible to integrate different loading capacities to the component - DLR-Patent is able to be incorporated at any stage and position in the vehicle development process Var 1 Var 2 - Increasing volume - Increasing range of CNG-vehicles - Increasing customer benefits - Lowering weight

18 Slide 18 (I) LEICHT Potentials - Combines the advantages of wheel hub motor and center drive - Complete solution for the powertrain and chassis - Protection of the drive against impact, abuse, acceleration - High degree of modularisation - Power, torque - Hybridisation - Front wheel application - Decreasion mass - Increasing volume - Increasing range of EV - Increasing vehicle applications

19 Slide 19 Outlook - Function-integrated Lightweight Design Structures for Next Generation Ground Vehicles - Improved lightweight solutions (new materials and combination of materials) - New function integrated solutions (mechanical, thermal, electric, ) - Solutions applicable in different series - DLR Institute of Vehicle Concepts: - (I) LEICHT : Prototyping for functional demonstration - (II) DLR Wabentank : Validation of concept

20 Function-integrated Lightweight Design Structures for Next Generation Ground Vehicles , IEA Workshop Dipl.-Ing. Gundolf Kopp Head of Lightweight and Hybrids Design Methods DLR Institute of Vehicle Concepts Stuttgart

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