Comparison of unibody and frame body versions of ultra efficient electric vehicle

Abstract

When designing an ultra energy-efficient vehicles it is extremely important to ensure the lightweight vehicle's structure. The compromise between the fulfilment of functional and strength requirements can be achieved by using a spatial shell or frame design. The paper presents a comparison of these two concepts of the supporting structure of such a vehicle, at the same time analysing the pros and cons of each of them. The method of optimizing the structure of both load carrying structures was proposed, as well as technical, technological and functional details related to these concepts were analysed. For the purposes of optimization, the method of topological optimization was used, modifying the assumptions for each of these concepts and iteratively adapting to the specific technology of making the vehicle's body. The numerical simulations were carried out for a previously selected outside vehicle's surface, optimized in order to minimize the aerodynamical resistance forces.

Lightweight Beam Structure Topology Design Solution for Steel and Aluminum Hybrid Body

“…Figure 2 shows the production process of different types of threshold beams, and the comparison shows that the production process of Al profile threshold beams is shorter and has better formability. In addition, based on the characteristics of Al profiles with equal cross-section, the development process only needs to focus on the cross-sectional characteristics of Al profiles [14], and the design difficulty is lower than that of sheet metal parts. At the same time, Al alloy has a better energy absorption effect in case of collision to ensure the safety of cabin members [15][16][17].…”

Design and development of ultra-light front and rear axle of experimental vehicle

“…One of these losses can be caused by the poor geometry of the steered wheels, which can cause the steered wheels to brake the entire vehicle when cornering [5,6]. Despite the fact that the ultra-light vehicle does not have dampers, it was necessary to think about the stiffness of the axle so that it could to some extent support the wheel and return to the original position [7][8][9]. An important factor for the success of these races is not only to build a low consumption engine, but also to reduce wheel resistance, especially when cornering [10,11].…”