OPERA4FEV - OPerating Energy RAck for Full Electric Vehicle
Overview
Background & policy context:
The project was funded under the call FP7-2011-GC-ELECTROCHEMICAL-STORAGE 'Advanced eco-design and manufacturing processes for batteries and electrical components'.
Further development and deployment of electrical vehicles call for large scale production of batteries and electrical components with good performances and at the lowest possible cost. Research shall address the whole value chain including the eco-design, assembly/integration and production of batteries and electrical components (motors, battery management systems, etc.). Eco-design should properly account for the relevant dismantling, recycling/disposal, and health and safety aspects of critical materials.
Objectives:
The goal of the OPERA4FEV project is to develop thermoplastic battery racks on two functional demonstrators: one for a large scale vehicle from FIAT and one for a 'niche' car, the F-City from FAM. To improve deployment of electrical vehicles in Europe, large scale production processes for rack and electrical components need to be developed.
Methodology:
OPERA4FEV will integrate electrical, hydraulic connections, and component housing in a thermoplastic approach to reduce costs, weight, and assembly time.
In order to demonstrate the relevance of the solution and meet strong industrial benefits, the two thermoplastic racks will be manufactured and assembled industrially. The whole value chain will be addressed, including the eco-design (dismantling and recycling of critical materials), assembly and integration of cells and electrical components.
As safety of the on-board battery in electric, hybrid, and plug-in vehicles is of paramount importance to the international auto industry, OPERA4FEV will pay particular attention to evaluating the effects of the rack characteristics with regard to vehicle crash safety, and will focus on the potential risks for the vehicle and its occupants in case of failure of one or more batteries.
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