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TRENDS in LIGHTWEIGHTING of Bevs: a REVIEW of STRATEGIES – Part II

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TRENDS in LIGHTWEIGHTING of Bevs: a REVIEW of STRATEGIES – Part II TECHNOLOGY FORESIGHT LIGHTWEIGHTING TRENDS IN LIGHTWEIGHTING OF BEVs: A REVIEW OF STRATEGIES – Part II Electric vehicle (EV) is not just a change in fuel, or energy source. It is a new paradigm in mobility and hence it brings with it possibilities of disruptive innovations in the way a vehicle, or even the transportation system, is de- signed. The future lightweight EVs, thus, may adopt lightweighting strategies that not only covers innovations in materials, design and joining technologies, but also in the form of new approaches towards systems integration, drivetrain configurations, packaging, and thermal management, et cetera. This the second of the two-part article on lightweighting trends of BEVs. 18 www.autotechreview.com AUTHORS LIGHTWEIGHT BODY AND COMPONENT DESIGN Traditional approaches towards light- weighting of vehicles include use of light- weight materials (both for structure, clo- sure panels as well as powertrain compo- SURESH BABU MUTTANA nents), structural design, and joining is Scientist C at TIFAC, Department technologies. For EVs, new concepts like of Science & Technology, Government of India. use of body panel for energy storage are being explored. Use of Lightweight Materials: Significant work has been reported on reducing vehicle mass, wherein conven- tional steel is replaced with lightweight materials such as advanced high strength RAKESH KUMAR DEY steels (15-25 %), aluminium (40-60 %), is Project Associate at TIFAC, carbon fibre (50-60 %) and magnesium Department of Science & (60-75 %). Body-in-White (BIW), closure Technology, Government of India. panels and powertrain components have been developed using these lightweight materials, while monocoque frame, space frame and multi-material designs, 1, have also been explored. Such efforts help in developing lightweight and energy effi- ARGHYA SARDAR cient vehicles. is Scientist E & Head, Transportation Use of Body Panels for Energy Storage: Division at TIFAC, Department of What if the body panels of the car itself Science & Technology, Government of India. are made as a battery? Carbon fibre is a suitable material for this purpose, as it can fulfil two functions in an electric car – as a lightweight composite reinforcement material for the car’s body, and as an active electrode in lithium-ion batteries. The idea is to develop a structural battery consisting of multifunctional lightweight materials that simultaneously manage mechanical loads, and store electrical energy. This can result in a weight reduc- tion for EVs. A project by British researchers and Volvo Cars used multi-layer carbon fibre body panels that store electricity, serving as a battery or as a capacitor. A material composed of carbon fibre, nano-struc- tured batteries and super-capacitors, cre- ating a sandwich of materials that can take on the shape of body panels of a car and store and charge energy, was used. The material can be moulded and formed to fit around the car’s frame in locations such as door panels, trunk lid and wheel bowl, substantially saving on space. The skin of the vehicle would essentially act as one large thin, lightweight battery. A carbon fibre-based composite forms the electrodes in the novel energy storage units. Carbon fibres are coated with car- autotechreview October 2014 Volume 3 | Issue 10 19 TECHNOLOGY FORESIGHT LIGHTWEIGHTING 1 Citroën C4 Cactus AIRFLOW 2L concept to be unveiled at the Paris Motor Show uses multi-materials bon nanotubes (CNT), where additionally Graphene is a material made from a single for reducing the emission of smoke), incorporated lithium atoms increase con- layer of carbon atoms, which is stronger and superior durability, 3. ductivity. The composite of carbon fibres than diamond, is lightweight and is flexi- The University of Sunderland, work- and CNTs is embedded in a polymer resin ble. This ‘wonder material’ has the poten- ing with a consortium of five research and glass fibre mats between the energy- tial to stimulate more sustainable trans- partners from Italy, Spain and Germany, saving layers serve as insulation. This port with light and ultra-efficient batteries under iGCAuto proposal, have been allows the materials to be used as and can be used in ultra-capacitors, solar investigating to understand and analyse super-capacitors. cells and as lightweight materials for vehi- the properties of graphene to determine Components in the Volvo S80, such as cle body applications. how it behaves, when it is used to the trunk lid were developed using the Graphene has tremendous applica- enhance the advanced composite mate- above materials. Structural super-capaci- tions for the automotive industry and rials used in the production of cars. A tor laminates are integrated on the outer using it to enhance the composite mate- novel graphene based in the fabrication skin of the trunk lid. The material was rials in cars has large potential. Gra- of nano-composites with different poly- recharged and energised by the use of phene, providing unprecedented mer matrices will be investigated, mod- brake energy regeneration in the car or by mechanical characteristics, could offer elled, and designed to enhance both plugging into the electrical grid. It then the desired solution. This material will vehicle and occupant safety; yet remain transfers energy to the electric motor, provide benefits such as improved very light. The challenge here is not which is discharged as it is used around strength, dimensional stability and bet- only producing graphene-based prod- the car. The research results showed that ter thermal behaviour, better flame ucts, but also applying them on a large- this material charges and stores energy behaviour (active as flame retardant and scale in cars [6]. faster than conventional batteries can. It is also strong and flexible. This work is The latest nanomaterials made of extremely being accompanied by development of an thin and strong carbon fibre replaces the car’s steel body panels and can be used in electrically conductive epoxy resin for the car’s roof, doors, bonet and floor, These panels also double up as the car’s battery. fibre-reinforced composites [4]. Volvo suggests that the complete sub- stitution of an electric car’s existing com- ponents with the new material could cut Expected range is the overall weight by more than 15 %, 2. 130 km when the doors, roof and This is not only cost-effective but would bonnet are replaced. -15% also have improved impact on the envi- The car’s weight can be ronment [4]. If future composite battery reduced by 15%. There is potential for cutting weight 130 km structures could store energy as efficiently still further. Electrons (•) as lithium-ion batteries, an EV would The body panels are require only the roof, hood and trunk lid Carbon fibre discharged as Ions (+) Fibreglass the car’s to be made of such materials to achieve electric motor The material can be recharged by Carbon Fibre an 80 ml (approximately 130 km) range. 1) harnessing the energy generated is used. when the car brakes Use of Graphene-Based Materials for 2) plugging into the mains electricity grid Structural Applications: 2 Volvo's illustration of the benefits of using new materials 20 www.autotechreview.com Lightweight Graphene-based WIRING HARNESSES AND materials for structural applications IN-VEHICLE NETWORKS A large number of wiring harnesses are Graphene nanocomposites Nanostructured TE materials used in EVs to supply electricity and elec- for integrated sensors (cooling/heat recovery) trical/ electronic signals. Various func- Nanofluids tions in a conventional vehicle like engine Functional textile (friction/thermal management) management, power steering, windows control, wipers, air-conditioner, and light- Sensors for pollutants detection ing can be performed by electronic control and safety Smart adhesives units (ECUs), which vary in numbers in 3 Appplication of graphene in a car different type of vehicles. For example, there are two ECUs in the Tata Nano, and more than 100 in a Mer- high voltage cable length and supporting tery recharge system based on an Induc- cedes S Class car. Today, data communi- structure. The goal is to increase the peak tion Motor. The technique is to use the cation between ECUs is accomplished power density (kW/l) and peak specific motor as a set of inductors during charg- mostly by sending communication signals power (kW/kg). ing time to constitute a boost converter over dedicated wires, although network Weight and volume reduction of with the inverter to have unity power fac- protocols like CAN, LIN and FlexRay are power electronics components must be tor operation. With the use of inexpensive also used in a limited manner, mainly in done without affecting the efficiency, relays, the machine windings are reconfig- high-end vehicles. and at the same time, safety standards ured to be inductors in the charging time. In a midsize car, average weight of a must be maintained or enhanced. Differ- Thermal management system for wiring harness is about 45 kg. In an EV, ent components, which mainly contrib- power electronics in EVs add significant there are more number of ECUs for over- ute in weight and volume in power elec- amount of additional weight. This can be all vehicle management, battery control, tronics system of xEVs, include: (a) reduced, if the cooling requirement is less motor control, and other functions like outer case/ housing; (b) cooling system; stringent. Wide Band Gap (WBG) semi- brake, lighting, et cetera. Moreover, (c) inductors; (d) capacitors; (e) resistor conductor devices are able to operate at demand for electronics is increasing in and (f) high voltage cabling, switches, higher temperatures as compared to con- modern vehicles, for various functions sensors, etc. ventional silicon-based semiconductors. like navigation, intelligent transportation The on-board charger and the bi- Thus, use of WBG semiconductor devices system, and cruise control. This means directional DC/DC converter consist of can play a significant role in reducing the the complexity of wiring harness would similar kind of hardware, and hence can complexity of the cooling system and increase over a period of time.
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