Master's Programme in Mechanical Engineering, 60 credits MASTER Project Ecoist THESIS Conceptual design of the sheet-metal chassis for a three-wheel electrical vehicle Anne-Li Lundqvist and Christian Thomas Master Thesis, 15 credits Halmstad 2017-05-25 PREFACE Thank you all for supporting us in different ways in this master thesis! Examiner PhD Aron Chibba Halmstad University Supervisor PhD Håkan Petersson Halmstad University Supervisor Thomas Koch SirGomez Engineering AB Per Asterlind ArcelorMittal BE Group SSC AB Karl Johansson ESAB Sam Madsen Hoghtech AB Dr Anoop Chawla Indian Institute of Technology Patrik Hammarbäck Transportstyreslen Tanja Vainionpaa Transportstyreslen Bo Göringberg Transportstyreslen Luigi de Barone Svenska Fordonsbyggares Riksorganisation Robert Eriksson Svenska Fordonsbyggares Riksorganisation Gustaf Ridderstolpe Svenska Fordonsbyggares Riksorganisation Gustaf Ulander Svenska Fordonsbyggares Riksorganisation Peter Wounsch Svenska Fordonsbyggares Riksorganisation Peter Karlsson Swedish Standards Institute Herman Leufstadius Swedish Standards Institute Marie-Louise Bandelin Swedish Standards Institute Maria Nordqvist Sveriges MotorCyklister Ola Holmberg Weland AB Pece Ilievski Weland AB Lars Nord Weland AB Fredrik Påhlman Weland AB Peter Sköld Weland AB Anne-Li Lundqvist [email protected] [email protected] linkedin.com/in/annelilundqvist Christian Thomas [email protected] [email protected] linkedin.com/in/christian-thomas ABSTRACT Purpose The aim of the thesis is to aid the project Ecoist in further developing a chassis which needs be manufactural with reliable dimensions to prepare for a small pilot batch of units. Dimensions are intended to fluctuate at a minimum to greatly reduce- or completely remove the need for correcting actions during assembly. Approach To create a viable and functional product proposal, a thorough investigation of legal requirements and previously published material regarding chassis development was conducted. This information was then translated and integrated with the customer requirements provided during the initial consultation at the company. A draft of the intended product was designed through different CAD-software based on this information, which then in turn was further developed by multiple feedback sessions with the project owner. Findings The resulting product features a concept primary designed through sheet-metal based solutions, but also includes a lesser amount of complementary solutions based on pre-fabricated square pipes and a ready-made clamp system which was integrated into the structure, for economic benefit. Limitations The information acquired from the investigation of legal requirements have been regarded to as a foundation to improve the product quality, with respect to e.g. user’s functional- and perceived safety, and to pioneer for future certification. However, due to the business concept and the available timeframe, an international certification for making the vehicle eligible for the common commercial market was omitted. Furthermore, the FEM verification of the final product was postponed to future work resulting from inadequate software licensing levels, which disabled full access to the required functions. The safety-measures and dimensions are designed at the discretion the previous experience of the project owner. Keywords: Chassis design, Sheet-metal design, Ecoist Vehicle, i CONTENTS PREFACE .................................................................................................................. ABSTRACT .............................................................................................................. i CONTENTS ............................................................................................................ ii 1 INTRODUCTION ................................................................................................ 1 1.1 Background .................................................................................................... 1 1.2 Aim of the study ............................................................................................ 2 1.3 Limitations ..................................................................................................... 2 1.4 Individual responsibility and efforts during the project ................................. 4 1.5 Study environment ......................................................................................... 5 2 THEORY .............................................................................................................. 6 2.1 Summary of the literature study and state-of-the-art ..................................... 6 2.2 Chosen topic .................................................................................................. 9 3 METHOD ........................................................................................................... 31 3.1 Alternative methods ..................................................................................... 31 3.2 Chosen methodology for this project ........................................................... 31 4 RESULTS ........................................................................................................... 37 4.1 Presentation of experimental results ............................................................ 37 4.2 Presentation of results based on models and simulations ............................ 38 5 CONCLUSIONS ................................................................................................ 48 5.1 Discussion regarding validity of findings .................................................... 48 5.2 Conclusions drawn from the performed project .......................................... 49 5.3 Recommendation to future activities ........................................................... 49 6 CRITICAL REVIEW ......................................................................................... 51 6.1 Aspects ......................................................................................................... 51 6.2 What that could have been performed in a better way ................................ 52 References .............................................................................................................. 53 Appendix 1 Roll bar (ROPS) ................................................................................. 59 Appendix 2 SFRO Inspectors ................................................................................ 65 Appendix 3 Competitors ........................................................................................ 66 Appendix 4 EV Range at Lowest Costs ................................................................. 69 Appendix 5 Chassis Types and Development ....................................................... 70 ii Appendix 6 Ecoist Block Diagram ........................................................................ 77 Appendix 7 Examples of Cell Types and Their Chemistry ................................... 78 Appendix 8 Ecoist Batteries .................................................................................. 79 Appendix 9 Certificate Options ............................................................................. 85 Appendix 10 Technical Services in Sweden .......................................................... 87 Appendix 11 Study of Regulations During Design ............................................... 88 Appendix 12 Ecoist Regulation Flow Chart .......................................................... 89 Appendix 13 Motorcycle EU Regulations ............................................................. 90 Appendix 14 SFRO Regulations Guidance ........................................................... 91 Appendix 15 Surfaces and Radius ......................................................................... 92 Appendix 16 The Mechanical Design and product Support Process ..................... 94 Appendix 17 QFD .................................................................................................. 95 Appendix 18 Mathematica calculation example .................................................... 96 Appendix 19 Safety factor analysis ....................................................................... 97 iii 1 INTRODUCTION 1.1 Background The project Ecoist features the development of an electrically powered single person tricycle. The driver is protected from the elements by a completely transparent roof and windshield made as a homogeneous concept in Hammerglass©. The product aims to offer an eco-friendly solution to commute a shorter distance, typically travelable by bicycle. The idea behind this vehicle is that there are many people who live in location who can- and want to commute to, for example, a workplace on an everyday basis. However, there are several problems related to commuting without using a car. The most common choice for a person who want to travel in an eco-friendly way is to use public transportations. This is clearly a good option from an environmental friendly perspective, but within there lies an often-perceived negative aspect of becoming limited in when and where the route takes you, and often results in prolonged travel times and unexpected delays can disrupt your routine even further. Together with this aspect, you are also often required to carry any brought-along luggage or grocery bags bought all the way to, and from, the nearest bus- or train station. These couple of reasons generalized