Eco-Design of Lightweight Structural Components for Electric Vehicles Made of Advanced Materials
bookPart
The present paper showcases the results of the ALMA project, whose primary goal is to develop a novel electric vehicle structure for a passenger car, featuring reduced weight and environmental impact. Eco-design principles were incorporated from the early concept stages, integrating approaches like Design for Assembly and Disassembly (DFA/DFD), Design for Recycling (DFR), and func tional integration of separate parts into a single structure. A FORD Mondeo with Internal Combustion Engine (ICE) was chosen as a design baseline. Subsequent redesign and material selection iterations led to the development of a novel multi material Battery Electric Vehicle (BEV) concept, using Advanced High-strength steel (AHSS), low-density grade steel, laminate steel/plastic, and advanced Sheet Moulding Composite (SMC). Crash modeling was performed to virtually validate the design concepts against five different crash scenarios. Ultimately, the ALMA concept car’s final design can now boast a mass reduction of 160.5 kg, translating to a 22% weight reduction compared to the baseline BEV.
Topics
TNO Identifier
1018802
Publisher
Springer
Source title
Transport Transitions: Advancing Sustainable and Inclusive Mobility
Pages
796-801