ULTRALIGHT AND ULTRASAFE EFFICIENT ELECTRIC VEHICLE WEEVIL project RESOLVE project’s final event 2018/04/25 WEEVIL (Grant agreement no.: 653926) 1
Introduction Needs on road transport at EU cities: Reduce pollution & congestion Potential solution: Daily commute with L category EV Key aspects: Urban, Safe, Comfortable, Attractive, Performant, Affordable WEEVIL project: Individual innovations (applicable on different vehicles) + New vehicle = (next page) WEEVIL (Grant agreement no.: 653926) 2
WEEVIL concept WEEVIL Goals Encapsulated 3-wheeler Comfort - Urban vehicle in tad-pole configuration Full encapsulation for environmental protection. - Efficiency Comfortable seating space. - Safety No tilting/balancing. - Comfort - Affordability Joystick parking Low-cost fibre-reinforced Urban vehicle composite structure Minimum parking footprint Safety Affordability Composite-made structure with Non autonomous parking high specific energy absorption. Affordability Efficient magnet-free motor Low-cost composite structure (radically new high productivity Efficiency manufacturing process). New drive train with improved efficiency over the whole operating range. Efficiency Reduced vehicle weight. Affordability Magnet-free motor (no PM associated cost). Parking cross distance Interchangeable battery pack adapter (PINCER) Efficiency: Urban vehicle New battery management preventing degradation. Reduced footprint for tight roads/parking Affordability: Battery pack interchangeability: batteries from range/manufacturer best fitting user needs/budget. WEEVIL (Grant agreement no.: 653926) 3
Specifications, Vehicle layout and Styling (WP2) Objectives: Specifications: size, performance (speed, range). Components layout. 90 km/h 1.54 m Styling: 7 exterior, 3 interior 10 kW alternatives. > 80 km Off-the-shelf components. Ergonomic analyses: anthropometry, position and accommodation, roominess, visibility, ingress/egress. Mock-ups: exterior and interior, real size, 2 versions. WEEVIL (Grant agreement no.: 653926) 4
Specifications, Vehicle layout and Styling (WP2) Feature Description/Value Living in suburban area of big cities, they commute to the city every weekday, can charge Buyer’s profile the vehicle at home. * Cabin closed provides more comfort and safety than a bike. * Handling & Manoeuvrability as 4-wheel car. Car-like Comfort * Interior trim, feature, devices should be competitive to other same price range L category vehicle. Motorbike-like * Perpendicular parking in congested city, like bike is possible. (Pincer system) Parking-ability * Parking process including in-egress is as easy as bike. (Joystick Parking system) Autonomy range / * 80 km (at least). Charge * 4 hours NC & 30 min. (80%) QC Affordable Price 10 k€ including VAT (battery lease, etc. TBD) (Stress-less (VAT depends on country, price without VAT to be used for the Business Case) Commuter direction) WEEVIL (Grant agreement no.: 653926) 5
Specifications, Vehicle layout and Styling (WP2) Final style for prototype WEEVIL (Grant agreement no.: 653926) 6
Vehicle chassis and structure (WP3) Objective: Safe, light, affordable vehicle structure. Glass-fibre reinforced composite structure: 3x Specific Energy Absorption ▪ (SEA) than typical metal parts used in the crash structures of automobiles. New ultraviolet (UV)-cured pultrusion process: reduced cost. ▪ Result: A strong, durable and light weight structure design. ▪ Structural integrity target achieved for 40km/h frontal crash target (WP8). Chassis (WP3) and upperbody (WP7) structure manufacturing started. ▪ Physical test to be conducted at early 2019 . ▪ WEEVIL (Grant agreement no.: 653926) 7
Vehicle chassis and structure (WP3) 8
Vehicle chassis and structure (WP3) Limitations of the composites for a cost-effective industrialization • High cost of the raw materials • Low productivity of the manufacturing processes How can we solve the disadvantages of • Low automation (High labour cost) traditional pultrusion? Change the paradigm of traditional Pultrusion pultrusion and cure the profile out of the die M. MUSSELMAN. 2010 World Pultrusion Conference ✓ Continuous process Report. , 2010 ✓ High productivity ✓ Low influence of workforce Alternative fast curing method is needed ✓ Control of the resin percentage ✓ High mechanical properties in the Process restricted to constant radii longitudinal direction Ultraviolet curing (UV) Low productivity rates High pulling forces Constant cross section × High pulling forces × High investment of machinery × There are some Limited to straight profiles × variants but Curing inside the die www.fibrolux.com WEEVIL (Grant agreement no.: 653926) 9
Vehicle chassis and structure (WP3) Out of die UV cured pultrusion (curved profiles) WEEVIL (Grant agreement no.: 653926) 10
Electric motor (WP4) Objectives: compact, efficient, affordable. Magnet-free motor: no rear-earth, robust, efficient at wide speed range. ▪ Integrated gearbox: compactness. ▪ Integrated electronic driver: 2 power cables and 1 control connector interface ▪ Individual pole control: fault tolerance. ▪ Result: WEEVIL (Grant agreement no.: 653926) 11
Battery system (WP5) Objectives: Interchangeable battery- pack (≠ battery swop): ▪ Different chemistries, performances, prices. - Easy to remove. - Open communication protocol, standardized battery-vehicle interface. - Efficient: ad-hoc BMS, passive and active balancing, high accuracy and ▪ temperature monitoring to reduce degradation & increase efficiency. Ready to market. ▪ Results: BP Cells Chemistry Size (V) (A·h) (KW·h) Price (€) #1 Sinopoly LiFePo4 Prismatic 76,4 66 5,069 1430 #2 Kokam NMC Pouch 74 106 7,844 2690 +60 % +54 % +88 % WEEVIL (Grant agreement no.: 653926) 12
PINCER system (WP6) Objectives: reduced footprint, stability Wheels separation variation mechanism. ▪ Steering, suspension, and brakes compatible with PINCER while possessing ▪ good riding and dynamic behaviour when the mechanism is open. Results: Quarter cart tests: damper and suspension. ▪ PINCER tests: PINCER mechanism and steering. ▪ WEEVIL (Grant agreement no.: 653926) 13
PINCER system (WP6) High amplitude, low Hz, quarter car test PINCER test WEEVIL (Grant agreement no.: 653926) 14
Joystick parking concept Objectives: Minimum footprint parking. ▪ Simple, reduced cost. ▪ 1 2 3 ! PINCER 5 4 6 Driver get out Move slowly Perpendicular parking done! from the car by Joystick WEEVIL (Grant agreement no.: 653926) 15
Vehicle fabrication and integration (WP7) Objectives: Subsystems fabrication: upperbody structure, body panels, etc. ▪ Electrification. ▪ Vehicle assembly. ▪ Subsystems control calibration. ▪ Vehicle functional assessment. ▪ Body on frame 4 e-Motor and GBX Interiors Chassis and battery pack Pincer and front suspension WEEVIL (Grant agreement no.: 653926) 16
Vehicle fabrication and integration (WP7) Aluminium upperbody structure GFRP body panels Input CAD data Tooling engineering 4 Milling of moulds WEEVIL (Grant agreement no.: 653926) 17
Vehicle validation and homologation (WP8) Objectives: Vehicle prototype performance validation. ▪ Safety analysis : crash tests ▪ Vehicle homologation: guidelines and decisions (performance, safety,…) ▪ Approval and safety requirements for L5e-A category vehicle. - Parking places and curbs in European cities. - Requirements for vehicle lights, registration plate, bumper, front and rear - protective structures, doors, steering,… WEEVIL (Grant agreement no.: 653926) 18
Vehicle validation and homologation (WP8) Partial crash tests WEEVIL (Grant agreement no.: 653926) 19
End on May 2019 WEEVIL (Grant agreement no.: 653926) 20
WEEVIL Consortium Project Vehicle coordination manufacturer Vehicle styling Battery system Vehicle structure Composite structures Pincer system Test & Electric homologation motor WEEVIL (Grant agreement no.: 653926) 21
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