Ultra lightweight makes electric vehicles affordable

Ultra lightweight design makes electric vehicles affordable
Kim-Astrid Magister

Press office

Technical University of Dresden
31.08.2011 13:46
Ultra lightweight makes electric vehicles affordable
ILK Dresden scientists and LZS develop with its partner ThyssenKrupp an electric car under 900 kilograms - Research results for the first time at the 64th IAA 2011 presented

Dresden. The Institute for Lightweight Structures and Polymer Technology (ILK) Dresden University of Technology developed the lightweight center Sachsen GmbH (LZS) and ThyssenKrupp AG, a serial-capable ultra lightweight vehicle. The electrically powered compact car weighs less than 900 kilograms. Through consistent ultra-lightweight construction, the vehicle can take advantage of the benefits of a fully electric drive. The generic lightweight electric vehicle designed for the metro area and is particularly suitable for urban commuting and short distance drivers. Combine with this car project, the researchers sporty driving enjoyment with free attractive vehicle designs and environmentally friendly use.



From the study of electric vehicle - INECO
Ineco means "Composite Innovation Electro-Mobility" and is the name of the project vehicle, researching the experts of all involved project partners in a cooperative effort. Contrary to the common working practice to examine only the components of a vehicle and to substitute certain components with lighter, the research group considered the entire vehicle system. This holistic approach has led scientists to an innovative, integral composite construction that makes the project unique vehicle INECO.

To the production cost of the ultra-lightweight fiber used composite components, such as parts to reduce of carbon fiber reinforced plastics (CFRP), at a minimum, the INECO team in particular with the mass production compatible process design for this group of materials. The lean manufacturing processes are streamlined and automated. The approach here is in the integral composite construction. This can be compared to conventional designs, manufacturing and assembly operations and reduce cost-effectively produce high-quality raw materials in spite of vehicle components.

The consideration of individual vehicle components can not be neglected in spite of the holistic concept. On specially designed components demonstrators in Dresden, for example, tested the crashworthiness of various material combinations and verified. Thus, in dynamic experiments, the impact energy absorption capacity of the sill is tested. The conventional steel construction of the component is replaced with steel hybrid construction: - to create a mass-optimized structure - in the same crash performance.

Carbon steel makes tractable
Ultra lightweight for all system components is a top priority of INECO. The researchers are increasingly in use on a steel-CFRP hybrid construction. Where "the right material at the right place at the right price and with proper ecology" is used. Under the slogan "Carbon steel does soften up" the high ductility of steels with high energy absorption capacity of carbon fiber is combined, which allows extremely lightweight and crashworthy component solutions to be developed.

Innovation through integration
The structural components and the vehicle drive system of the research are planned Ineco highly integrative. By integral components, such as the one-piece vehicle floor structure, many functions and so embedded and mass production steps can be saved. Thus suitable for mass production and implementation of Ineco marketable concept is guaranteed.

The chassis is 120 kg with a true flyweight. Thus, the team proposes a new path in the body weight reduction. Together with ThyssenKrupp AG could be connected in the composite-steel hybrid construction, the excellent properties of steel and carbon fiber to a new mix of materials with low weight and good crash behavior.

The vehicle project Ineco the use of lithium-ion cells is also planned. The battery-containment is difficult and crash-neutral, secure integrated into the center of the vehicle in the soil structure and has a climate that always keeps the battery from "comfort temperature". With a range of 100 to 150 kilometers, the battery technology for high performance with comparatively low mass. The battery design is flexible and can equally flat, round and block include cell batteries. A permanent magnet synchronous electric motor with differential gear, the vehicle accelerates from 0 to 100 km / h in just 7.4 seconds.

Not least, the aesthetic appearance will decide on the successful acceptance of the electric vehicle. Ineco with scientists creating the step away from saving image of an electric vehicle, toward the sporty racer-ecological.

First presentation at the 64th IAA
On the 64th International Automobile Exhibition in Frankfurt am Main, the current research results of 15 to 25 September 2011 (Hall 4.0 / Stand D24) will be presenting. Especially for the first time a design model of the IAA Ineco was made, the 1:4 scale which gives visitors an idea of ​​the new electric car. In addition, the team presents a large series of tunnels capable pressed battery CRP, which is also developed by the project partners. Other exhibits are an innovative, ultra-light carbon fiber suspension and axle system with a newly developed hybrid-steel door sills in CFRP with extremely high energy absorption capacity.

This project is funded as part of the overall project ALIEN funds from the European Union - European Regional Development Fund (ERDF) - and the Free State of Saxony.

Press
Dresden Technical University | Institute for Lightweight Structures and Polymer Technology
Prof. Dr.-Ing. habil. Prof. E.h. Dr. h.c. W. Hufenbach
Holbeinstr. 3, 01307 Dresden
Telephone: (0351) 463 37 915 | E-mail: ilk@ ilk.mw tu-dresden de

Lightweight Design Centre Sachsen GmbH
J. Werner
Marschnerstr. 39, 01307 Dresden
Telephone: (0351) 463 39 477 | E-mail: werner@lzs-dd de

ThyssenKrupp Business Services
B. Stamm
Helenenstr. 110, 45143 Essen
Telephone: (0201) 844 545 185 | E-mail: bernd.overmaat @ thyssenkrupp.com