Making room for vehicle safety
Current designs for EVs take into consideration the need for lightweight bodies and components in order to optimise energy consumption. In addition, newly designed EVs have a completely different distribution of internal components with less architectural constraints. For instance, the front of a vehicle, traditionally used to accommodate the engine, now becomes a free space where other components can be installed. The EU-funded Optibody project is developing innovative passive safety solutions that help to reduce the effects of an accident. These solutions will initially be applied to electric light trucks or vans (ELTVs) under category L7e. This covers light vehicles where the unladen mass is not more than 400 kg or 550 kg for vehicles intended for carrying goods. Free spaces in EVs present an opportunity to implement new load paths and energy absorbers to protect the driver and passengers in the vehicle. The introduction of specific add-on components ensures enhanced protection for pedestrians, cyclists and road/urban infrastructure. The Optibody project represents the first example of components being specifically designed for implementation in a much less restrictive modular vehicle concept. The modularity approach – the degree to which components may be separated and recombined – allows for enhanced passive safety via the introduction of add-on components. It also provides increased flexibility of design, optimised ergonomics and space distribution, as well as improved conditions for repairs. Having completed the first stage of analysis of ELTVs' architecture, project partners defined the requirements and guidelines to identify the independent structural modules. These dealt with specific requirements regarding the rigidity, strength and energy absorption capacity of the modules. Research into the effects of front impact, side impact, rear impact and roll-over protection were completed. This was followed by testing of protection components in cases of interaction with traffic signals, light posts and other elements in the urban environment. Following the repairability and modularity analysis of the components, the chassis design was finished. This was finalised in line with the development of dedicated add-ons for front, rear, side and roll-over protection. These stages have lead to the final objective: the integration of a pilot demonstrator of the vehicle structure, including project-designed passive safety elements. Once the demonstrator has been integrated, it will be crash tested and the test results critically assessed according to the project requirements and applicable standards. The final project result is expected to be the definition, at European level, of an ELTV concept representing a high level of safety and modularity. This will provide an opportunity for manufacturers all over Europe to compete in the EVs market. Greater competitiveness implies higher quality and lower prices for EVs, from which all European citizens should be able to benefit.
