Small Urban Passenger Vehicle with CFRP-Aluminium Spaceframe Body Architecture

Composite Europe 2016

epsilon – Small Urban Passenger Vehicle with CFRP-Aluminium Spaceframe Body Architecture

Düsseldorf, 30. November 2016

Dipl.-Ing. Ralf Matheis, Dipl.-Ing. Johannes Stein, Dipl.-Ing. Kristian Seidel, Dipl.-Ing. Sven Faßbender, Dr.-Ing. Peter Urban, Univ.-Prof. Dr.-Ing. Lutz Eckstein

. Motivation . Project Overview . Concept Investigation . Development . Demonstrator Vehicle . Summary

Connectivity Urbanisation Accidents . Urbanisation is closely connected to the evolution Individualisation MOSKOW of mobility of mobility needs VIENNA OSLO ZURICH . 74% of European BIRMINGHAM FRANKFURT population lives in urbanised areas Demografic STOCKHOLM AMSTERDAM change LISBON MADRID BRUSSELS . Urban population will increase from 3.6 billion to COPENHAGEN NAPLES LONDON 6.3 billion between 2011 PARIS ATHEN and 2050 Limited Crime BERLIN MILANO CITY resources . New challenges in terms of BARCELONA STOCKHOLMCongestion COLOGN congestion as well as MARSEILLE MUNICH TORINO pollution and noise emissions BUDAPEST ROME LYON RIGA Public debt HAMBURG ANTWERP . Shared mobility and services become more Climate change ST. PETERSBURG important BIRMINGHAMICH Emissions Rising costs of energy and fuel

. Motivation . Project Overview . Concept Investigation . Development . Demonstrator Vehicle . Summary

#150 · 16rm0039.pptx Slide No. 4 2016/11/19 © ika 2016 · All rights reserved Project Overview Consortium small Electric Passenger vehicle with maximized Safety and Integrating a Lightweight Oriented Novel body architecture Funded by Funding Project Duration European Commission’s 2.5 Million Euro (project total) November 2013 to 7th Framework Programme February 2017

• Prototyping • Exterior and interior • Full vehicle integration finish and assembly

• CFRP rear axle • Project coordination • Concept investigation • Drivetrain layout • Exterior & interior design • Energy efficiency • Package • HVAC • Body design (CAE, CAD) • Drivetrain layout • Integral safety • HMI • Battery integration • Crash testing • Business case study • Active crash structures • Chassis design & build and restraints • Vehicle dynamics tests #150 · 16rm0039.pptx Slide No. 5 2016/11/19 © ika 2016 · All rights reserved Agenda

. Motivation . Project Overview . Concept Investigation . Development . Demonstrator Vehicle . Summary

L7e M1

Renault Twizy Efficiency Safety, Smart Fortwo E L: 2335 mm comfort L: 2695 mm W: 1228 mm W: 1559 mm H: 1454 mm H: 1565 mm

. Designing and prototyping the urban small electric vehicle of 2020 - 2025 . Appealing driving performance . Affordable costs . Lighter, more energy-efficient and compact than today's sub-compact cars . Higher safety, transport capacity and comfort than powered two-wheelers . Closing the gap between ultra light vehicles (L7e) and conventional cars (M1)

Concept Investigation Package

Concept Specification Sheet

Renault Twizy Tazzari Zero Smart Fortwo E Vehicle Type Exterior Dimensions L: 2335 mm L: 2880 mm L: 2695 mm W: 1228 mm W: 1560 mm W: 1559 mm Segment M0, Sub-A Length 3100 mm H: 1454 mm H: 1425 mm H: 1565 mm Seats 2 (M95th) + 1 (F5th) Width 1500 mm

Units per year 50,000 Height 1460 mm References SOP 2020 - 2025 Wheelbase 2040 mm Front track 1295 mm Technical Specs and Targets Rear track 1257 mm Curb weight 600 kg Gross vehicle weight 850 kg Interior Dimensions Battery capacity 15.6 kWh Headroom driver 980 mm cd x A 0.25 x 1.8 m² Range (urban) > 150 km Headroom co-driver 980 mm Max. velocity 120 km/h Headroom 2nd row 850 mm Acceleration (1-100 km/h) < 10 s Shoulder room front 1190 mm Electric motor 80 kW (Bosch) Shoulder room rear 1080 mm Gearbox ratio 1:9.59 (GKN) Trunk volume 100 – 260 l Front axle McPherson Functional Objectives Rear axle rigid axle Front tires 145/65 R15 Suitability for car sharing Rear tires 175/55 R15 Mainly for urban commuting Turning circle < 9 m Modularity for families NCAP rating 4 stars Easy to use Agile in urban environment

Concept Investigation Package

Final Package

Package concept Drivetrain development Vehicle concept

Chassis development

Cooler Charger HV battery Inverter; DC/DC Transmission Motor BiW development

. Motivation . Project Overview . Concept Investigation . Development . Demonstrator Vehicle . Summary

Development Structural BIW concept

Holistic lightweight design approach

Geometrical lightweight design Conceptual lightweight design Material lightweight design

Lightweight body

Topology optimisation

CAD model

. Lightweight design by . CFRP-Al-space-frame . Aluminium topology optimisation . Structurally integrated battery . CFRP . Structurally integrated rear seat

Body in White CFRP beam cross section . CFRP-aluminium space frame architecture Foam core . CRFP space frame enclosing the passenger compartment . Axontex technology by partner Axon . LPDE foam cores overbraided with HT carbon fibre . Additional braiding process leads to multi-chamber cross section . Filling with PU resin by VARTM in a tool . Curing in autoclave . Aluminium extrusion profile for front, rear and side deformation zones

Body in White Tailored CFRP shear GFRP exterior panels CFRP-Al-Space-Frame panels and nodes (non-structural)

8 kg BIW 21 kg 4 % 10 % Doors and closures

35 kg Exterior 17 % 112 kg Glazing 53 % 35 kg Hang-on 16 % parts/brackets

Static load cases Bending Stiffness Torsion Stiffness

kN kN  c 19.313  c 31.175 Bending mm Torsion 

z z y x y x

Translation locked Translation locked Translation locked Translation locked in Y, Z in X, Y, Z in Z in X, Z

mBIW Lightweight quality index: 퐿푇 = = 1.38 cT ∙ AT

Crash load cases

1 3 5

2 4 6

# Crash Test 1 Euro NCAP full width rigid barrier front crash  2 Euro NCAP offset deformable barrier front crash  3 Euro NCAP moveable deformable barrier side crash  4 Euro NCAP side pole crash  5 FMVSS 216 roof test  6 FMVSS 301 offset deformable barrier rear crash 

Euro NCAP full width rigid barrier front crash

video

Front and rear axle

. McPherson front suspension and steering system have been derived from the ones of a donor vehicle with minor adaptations.

. An Omega beam rear axle has been specifically designed for the epsilon vehicle with the aim of: . assuring a good K&C performance . weight reduction (37%) with hybrid metal/CFRP solution

6 5 1: Middle section (CFRP) 4 2: Connection with central joint (metal) 3: Connection between middle and side section 4: Side section (metal) 3 5: Wheel trunk (metal) 1 6: Connection with the Watt-linkage (metal) 2

[CRF]

Drivetrain architecture

Inverter/converter . Driving efficiency and performance determined for WLTP-C3 in HIL test: Transmission . 156 km driving range Electric motor @ 90% SOC to 15% SOC . 76 Wh/km energy demand . 8.9 s to 100 km/h High voltage battery . Integrated power distribution unit . Cell type: Panasonic 18650PF . 110 kg (25% less than liquid-cooled version) . Voltage (nom.): 367 V . Three additional electric connectors for fast . Energy content: 15.6 kWh (DoD of 75%) charging, PTC heater, refrigerant compressor

. Motivation . Project Overview . Concept Investigation . Development . Demonstrator Vehicle . Summary

Prototyping

Body structures Full vehicle integration

Drivetrain system Omega beam

Testing

video

. Motivation . Project Overview . Concept Investigation . Development . Demonstrator Vehicle . Summary

. The epsilon concept shows a prototype for an urban small electric vehicle of 2020 - 2025. . Specifically designed for the typical transport tasks in urban areas, based on a scenario and market analysis . The minimalistic vehicle concept shows a safe & efficient urban mobility concept. . A running prototype vehicle has been built to demonstrate a new vehicle class to possible customers and stakeholders. . epsilon . closes the gap between L7e vehicles and conventional cars (M1), . is lighter and more energy efficient than today's sub-compact cars, . offers higher safety, transport capacity and comfort compared to powered two-wheelers (PTWs) and ultra light vehicles.

Funded by the Seventh Framework Programme of the European Union

On behalf of the epsilon team

Dipl.-Ing. Ralf Matheis

fka Forschungsgesellschaft Kraftfahrwesen mbH Aachen Steinbachstr. 7 52074 Aachen Germany

Phone +49 241 88 61121 Fax +49 241 80 22147