Investigation in To Body in White In Relation To Electric Vehicles

By

ABSTRACT

The Automotive Composites Consortium has initiated the third of a series of focal projects, which is a multiyear program to develop a design and manufacturing strategy for a composite intensive body-in-white (BIW) with aggressive mass reduction, manufacturing cycle time, and cost parity targets. Specifically, the BIW is to exhibit 60% minimum mass savings over the conventional steel baseline, contain the same package space as the baseline, meet or exceed the structural performance, and have cost parity to the baseline in volumes exceeding 100,000 per annum. The Department of Energy's Office of Advanced Automotive Technology provided most of the funding for this project. A design study was undertaken to evaluate whether the mass savings are feasible - utilizing carbon-fiber composites - without sacrificing structural performance. The design was conducted with consideration to costeffective composites manufacturing processes that are under development. This paper will present objectives of this focused program, results of the design study, and a discussion of the technical challenges that will be addressed during the remainder of the program.

ACKNOWLEDGEMENT

I would take this opportunity to thank my research supervisor, family and friends for their support and guidance without which this research would not have been possible.

TABLE OF CONTENTS

ABSTRACTII

ACKNOWLEDGEMENTIII

GLOSSARYVI

CHAPTER 1: INTRODUCTION1

Background of the study1

Problem Statement2

Purpose of the study2

Rationale of the study2

Aims & Objectives4

Scope of the study5

Significance of the study9

CHAPTER 2: LITERATURE SEARCH12

Body-in-White (BIW) Engineering & Manufacturing solution12

General Motor Performance Parts to Provide $7,000 Body-In-White (BIW) New Camaro12

Body in White Solutions13

Global advantages15

Production Process Of Body-In-Withe (BIW)15

Automotive body assembly17

Electric Vehicle17

Energy sources19

Consumption21

Pollution26

Contamination of Electricity27

Integration into the grid30

Operation30

Hybrids31

Trademarks and pioneering models32

Betting Government for change32

Promotion33

OECD33

European Union33

Teachings34

CHAPTER 3: METHODOLOGY35

Theoretical Framework35

BIW Focal Project Phases36

Preliminary Design And Analysis Of The Body-In-White (BIW)36

Conceptualization Of The Body-In-White37

Concept Development38

Design Concepts38

CHAPTER 4: ANALYSIS & RESULTS41

Detailed Design and Analysis Of Bodyin-White (Biw)41

Final Design And Part Break-Up42

Analysis Results43

Abuse Loads44

Modal Analysis45

Part Thickness46

CHAPTER 4: DISCUSSION47

Climate change and CO2 emissions49

CHAPTER 5: CONCLUSIONS54

REFERENCES64

GLOSSARY

BIW: Body in White

EV: electric vehicle

BEV: battery electric vehicle

CENELEC: European Committee for Electro-technical Standardization,

EREV: extended-range electric vehicle

FCV: fuel cell vehicle

FEV: Full Electric Vehicles

GHG: green house gas

HEV: full hybrid vehicles

ICE: internal combustion engine

IEC: International Electro-technical Commission

ISO: International Standardization Organisation

PHEV plug-in hybrid electric vehicle (including range extenders)

CHAPTER 1: INTRODUCTION

Background of the study

The improvement in technologies that results in a considerable mass reduction is the basis on which successful installation of exceedingly fuel-efficient vehicles rely on. To that point, the U.S Council for Automative Research (USCAR) and United States Department of Energy Office of Transportation are starting research programs to improve manufacturing processes, assembly methods and latest materials for automotive structures. In order to get Structural applications, the improvement of polymer-matrix composite technology are one of the main areas of this research. One of the consortiums under USCAR, the Automotice Composites Consortium (ACC) after its inception in the late 1980's has kept it in its focus. Mass reductions of up to thirty percent as compared with the common steel structures can be attained by structural components as demonstrated in latest success with glass-reinforced polymers. Glass fibre composites can achieve upper limit ...