Overview
At the start of this project, the automotive industry had not yet decided which architecture solution for electric vehicles was optimal. This and the fact that requirements and constraints derived from an electrical power-train were much less stringent in several areas made it necessary to study new solutions specifically designed for the particularities of electric vehicles.
The E-LIGHT project aimed at exploring all the aspects and requirements for optimal electric vehicle architectures. These particularities were studied in the E-LIGHT project, focussing on:
- Modularity of components;
- Ergonomic designs;
- Innovative safety concepts;
- Better aerodynamic performance and lesser weight which would decrease the overall power consumption and consequently will increase the range.
The main objective of E-LIGHT project was to develop an innovative multi-material modular architecture specifically designed for electric vehicles, achieving optimal light weight and crash worthy performances while ensuring ergonomic standards on board.
In order to achieve this objective, the following scientific and technical objectives were defined:
- Identification of architectural requirements for future electric vehicles, focussing on lightweight for different battery and electric motor configurations(front or rear stand alone, wheel in hub);
- Identification of optimal multi-materials solution to become part of the electric vehicles architectures;
- The optimal geometries and designs for the EV architectures, taking into account previously studied architectural requirements and materials;
- Definition of design methodology and testing procedures in order to develop general design guidelines and testing procedures towards more sustainable, lightweight, modular concepts of the design process.
Funding
Results
The first activity carried out during e-LIGHT was addressing lightweight design by exploring the differences regarding conventional internal combustion engine (ICE) architectures. In particular, the requirements for future EVs set the basis of the whole work and defined the design drivers and the design matrix. This matrix was an instrument that cross-referenced different solutions against a list of key factors. Each factor was characterised by a score. The solutions were ranked through the weighted scores. In this way, the best solution could be identified and selected for the next steps.
A trade-off of materials model was developed, applicable to the development of urban EVs. Technical requirements, preferred design concepts and manufacturing processes were taken into account, all of which were direct results of the work performed in analysing the requirements of EVs. Two main families of materials were chosen according to the defined criteria:
- technical thermoplastic materials for injection and glass mat thermoplastic (GMT) processes to ensure critical technical requirements of materials;
- thermoset materials for liquid moulding processes, such as resin transfer moulding (RTM), casting and RTM-Var, to ensure economical feasibility for short runs.
In both cases, the pre-finished sheet had the best score regarding the preferential design concepts.
The main result achieved in the study of advanced metallic materials was to establish a short list of materials susceptible to be used in the BIW of the project vehicle. It was concluded that the aluminium had a great potential to be used in almost all the processes considered:
- 6 005 A T6 would be considered for the extruded components;
- 6 111 T4 would be considered for panels; and
- AlSi7Mg would also be considered.
The magnesium alloys were rejected as structural components, although some other uses were found in internal structures and components' covers. The metal matrix composites (MMCs) were estimated as not suitable for their application, due to their lack of application in structural components and the high cost of the rest of possible applications.
The values of the matrices used in the analysis of joining techniques and manufacturing processes were extracted directly from the descriptive of materials, processes and joining technologies. The process selection was mainly based on the underlying design concept and the degree of integration. Furthe
Policy implications
E-LIGHT results were anticipated to have a significant impact in enhancing the European automotive industry competitiveness, allowing for a closer and improved relationship between original equipment manufacturers (OEMs) and large companies in this industry with the SMEs in their supply chain. By increasing their knowledge, E-LIGHT would facilitate European SMEs in the automotive market to consolidate their position while improving their adaptation towards the new requirement of electric mobility.
In addition, the E-LIGHT results aimed to support and boost the European automotive industry competitiveness, especially their SMEs, to continue being a pillar of the European economy, representing 3 % of Europe's gross domestic product, 7 % of employment in the manufacturing sector and 8 % of the European Union governments' total revenue.
Strategy targets
Innovating for the future: technology and behaviour
- Promoting more sustainable development