WEEVIL project RESOLVE projects final event 2018/04/25 WEEVIL - - PowerPoint PPT Presentation

ULTRALIGHT AND ULTRASAFE EFFICIENT ELECTRIC VEHICLE

1 WEEVIL (Grant agreement no.: 653926)

WEEVIL project

RESOLVE project’s final event 2018/04/25

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)

2 WEEVIL (Grant agreement no.: 653926)

WEEVIL concept

3 WEEVIL (Grant agreement no.: 653926)

Joystick parking

Safety Composite-made structure with high specific energy absorption. Affordability Low-cost composite structure (radically new high productivity manufacturing process). Efficiency Reduced vehicle weight. Comfort Full encapsulation for environmental protection. Comfortable seating space. No tilting/balancing. Efficiency New drive train with improved efficiency over the whole operating range. Affordability Magnet-free motor (no PM associated cost). Efficiency: New battery management preventing degradation. Affordability: Battery pack interchangeability: batteries from range/manufacturer best fitting user needs/budget. Urban vehicle Reduced footprint for tight roads/parking WEEVIL Goals

• Urban vehicle
• Efficiency
• Safety
• Comfort
• Affordability

Low-cost fibre-reinforced composite structure Encapsulated 3-wheeler in tad-pole configuration Efficient magnet-free motor Interchangeable battery pack Parking cross distance adapter (PINCER)

Urban vehicle Minimum parking footprint Affordability Non autonomous parking

Specifications, Vehicle layout and Styling (WP2)

4 WEEVIL (Grant agreement no.: 653926)

Objectives:

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Specifications: size, performance (speed, range).

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Components layout.

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Styling: 7 exterior, 3 interior alternatives.

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Off-the-shelf components.

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Ergonomic analyses: anthropometry, position and accommodation, roominess, visibility, ingress/egress.

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Mock-ups: exterior and interior, real size, 2 versions.

1.54 m

90 km/h 10 kW > 80 km

Specifications, Vehicle layout and Styling (WP2)

5 WEEVIL (Grant agreement no.: 653926)

Feature Description/Value

Buyer’s profile Living in suburban area of big cities, they commute to the city every weekday, can charge the vehicle at home. Car-like Comfort * Cabin closed provides more comfort and safety than a bike. * Handling & Manoeuvrability as 4-wheel car. * Interior trim, feature, devices should be competitive to other same price range L category vehicle. Motorbike-like Parking-ability * Perpendicular parking in congested city, like bike is possible. (Pincer system) * Parking process including in-egress is as easy as bike. (Joystick Parking system) Autonomy range / Charge * 80 km (at least). * 4 hours NC & 30 min. (80%) QC Affordable Price (Stress-less Commuter direction) 10 k€ including VAT (battery lease, etc. TBD) (VAT depends on country, price without VAT to be used for the Business Case)

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Final style for prototype

Specifications, Vehicle layout and Styling (WP2)

Vehicle chassis and structure (WP3)

7 WEEVIL (Grant agreement no.: 653926)

Objective: Safe, light, affordable vehicle structure.

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Glass-fibre reinforced composite structure: 3x Specific Energy Absorption (SEA) than typical metal parts used in the crash structures of automobiles.

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New ultraviolet (UV)-cured pultrusion process: reduced cost. Result:

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A strong, durable and light weight structure design. Structural integrity target achieved for 40km/h frontal crash target (WP8).

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Chassis (WP3) and upperbody (WP7) structure manufacturing started.

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Physical test to be conducted at early 2019 .

Vehicle chassis and structure (WP3)

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• M. MUSSELMAN. 2010 World Pultrusion Conference
• Report. , 2010

✓ Continuous process ✓ High productivity ✓ Low influence of workforce ✓ Control of the resin percentage ✓ High mechanical properties in the longitudinal direction

Pultrusion

There are some variants but Process restricted to constant radii Low productivity rates High pulling forces × Constant cross section × High pulling forces × High investment of machinery × Limited to straight profiles

• High cost of the raw materials
• Low productivity of the manufacturing processes
• Low automation (High labour cost)

Limitations of the composites for a cost-effective industrialization

www.fibrolux.com

Curing inside the die

How can we solve the disadvantages of traditional pultrusion? Change the paradigm of traditional pultrusion and cure the profile out of the die Alternative fast curing method is needed Ultraviolet curing (UV)

Vehicle chassis and structure (WP3)

10 WEEVIL (Grant agreement no.: 653926)

Out of die UV cured pultrusion (curved profiles) Vehicle chassis and structure (WP3)

Electric motor (WP4)

11 WEEVIL (Grant agreement no.: 653926)

Objectives: compact, efficient, affordable.

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Magnet-free motor: no rear-earth, robust, efficient at wide speed range.

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Integrated gearbox: compactness.

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Integrated electronic driver: 2 power cables and 1 control connector interface

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Individual pole control: fault tolerance. Result:

Battery system (WP5)

12 WEEVIL (Grant agreement no.: 653926)

Objectives:

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Interchangeable battery-pack (≠ battery swop):

• Different chemistries, performances, prices.
• Easy to remove.
• Open communication protocol, standardized battery-vehicle interface.

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Efficient: ad-hoc BMS, passive and active balancing, high accuracy and temperature monitoring to reduce degradation & increase efficiency.

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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 %

PINCER system (WP6)

13 WEEVIL (Grant agreement no.: 653926)

Objectives: reduced footprint, stability

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Wheels separation variation mechanism.

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Steering, suspension, and brakes compatible with PINCER while possessing good riding and dynamic behaviour when the mechanism is open. Results:

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Quarter cart tests: damper and suspension.

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PINCER tests: PINCER mechanism and steering.

PINCER system (WP6)

14 WEEVIL (Grant agreement no.: 653926)

High amplitude, low Hz, quarter car test PINCER test

Joystick parking concept

15 WEEVIL (Grant agreement no.: 653926)

Objectives:

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Minimum footprint parking.

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Simple, reduced cost.

Perpendicular parking done! 1 2 3 4 5 6

!

PINCER Move slowly by Joystick Driver get out from the car

Vehicle fabrication and integration (WP7)

16 WEEVIL (Grant agreement no.: 653926)

Objectives:

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Subsystems fabrication: upperbody structure, body panels, etc.

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Electrification.

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Vehicle assembly.

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Subsystems control calibration.

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Vehicle functional assessment.

4

Interiors Pincer and front suspension Body on frame e-Motor and GBX

Chassis and battery pack

Vehicle fabrication and integration (WP7)

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4 Milling

• f moulds

Input CAD data Tooling engineering GFRP body panels Aluminium upperbody structure

Vehicle validation and homologation (WP8)

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Objectives:

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Vehicle prototype performance validation.

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Safety analysis : crash tests

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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,…

Partial crash tests

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Vehicle validation and homologation (WP8)

End on May 2019

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WEEVIL Consortium

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Project coordination Vehicle styling Vehicle structure Pincer system Electric motor Vehicle manufacturer Battery system Composite structures Test & homologation