Low-cost lightweight electric vehicles body concepts
Lowering the weight of transport vehicles that run on internal combustion engines (ICEs) has become increasingly relevant in recent years as a route to reduce fuel consumption and emissions. Lesser weight is also a target of EV designers as it would increase the currently limited driving range before needing recharging. Insight can be drawn from the years of research on ICE-powered vehicles, but key differences exist in design constraints and in crash behaviours. A powerful EU consortium launched the project ALIVE (Advanced high volume affordable lightweighting for future electric vehicles) to address all relevant issues. The team had 21 partners – seven car manufacturers, seven suppliers, two small and medium-sized enterprises, and five research organisations. Together, partners worked on developing low-cost solutions for the design of lighter vehicles produced in high volumes (1 000 vehicles per day). The ALIVE scientists aimed for a body in white weight of 200 kg. Its approach centred on the use of innovative high-strength materials such as steel, aluminium and fibre reinforced plastic (frp) and their respective assembly processes. The front body was designed with three paths to lead crash loads into the vehicle body structure. The upper body consisted mainly of aluminium sheets, while the A- and B-pillars were partly made of hot formed high-strength steel. Aluminium was used in the front and rear doors, achieving weight savings of around seven and three kg, respectively. The roof prototypes consisted of an frp sandwich structure and glued aluminium cross-members. Scientists generated interest through presentation of the project at a number of important industry events such as the European Council for Automotive R&D (EUCAR) conference and the Electric Vehicle Symposium. Project success will put the EU in a leadership position in an emerging market on the verge of a major breakthrough and tremendous global uptake. Aside from the socioeconomic implications for the well-being of the EU economy and its citizens, widespread use of Evs will have major impact on emissions and global climate change.
Keywords
Lightweight, electric vehicles, multi-material, body-in-white, aluminium
