Design of Eco-Efficient Body Parts for Electric Vehicles Considering Life Cycle Environmental Information

Abstract

The reduction of greenhouse gas (GHG) emissions over the entire life cycle of vehicles has become part of the strategic objectives in automotive industry. In this regard, the design of future body parts should be carried out based on information of life cycle GHG emissions. The substitution of steel towards lightweight materials is a major trend, with the industry undergoing a fundamental shift towards the introduction of electric vehicles (EV). The present research aims to support the conceptual design of body parts with a combined perspective on mechanical performance and life cycle GHG emissions. Particular attention is paid to the fact that the GHG impact of EV in the use phase depends on vehicle-specific factors that may not be specified at the conceptual design stage of components, such as the market-specific electricity mix used for vehicle charging. A methodology is proposed that combines a simplified numerical design of concept alternatives and an analytic approach estimating life cycle GHG emissions. It is applied to a case study in body part design based on a set of principal geometries and load cases, a range of materials (aluminum, glass and carbon fiber reinforced plastics (GFRP, CFRP) as substitution to a steel reference) and different use stage scenarios of EV. A new engineering chart was developed, which helps design engineers to compare life cycle GHG emissions of lightweight material concepts to the reference. For body shells, the replacement of the steel reference with aluminum or GFRP shows reduced lifecycle GHG emissions for most use phase scenarios. This holds as well for structural parts being designed on torsional stiffness. For structural parts designed on tension/compression or bending stiffness CFRP designs show lowest lifecycle GHG emissions. In all cases, a high share of renewable electricity mix and a short lifetime pose the steel reference in favor. It is argued that a further elaboration of the approach could substantially increase transparency between design choices and life cycle GHG emissions.

Techno-Economic and Sustainable Challenges for EV Adoption in India: Analysis of the Impact of EV Usage Patterns and Policy Recommendations for Facilitating Seamless Integration

“…Figure 10 gives an overview [93] of the various initiatives taken by the government to boost Renewable Energy adoption in India. Some of the other measures taken are a) waiver of Inter-State Transmission System (ISTS) charges for inter-state sale of solar and wind power for projects to be commissioned by 30th June 2025, laying of new The research community [94], [95], [96] also has been addressing various aspects of sustainability in the form of various ecological and lifecycle assessments. Prioritizing renewable energy [97], efficient battery recycling, and infrastructure improvements are vital for EV sustainability.…”

Holistic eco-design tool within automotive field

“…The only studies that integrate sustainability aspect into the design process using a systematic computer-aided design procedure are Reimer et al [21], Russo and Matina [22] and Russo and Rizzi [23]. Reimer et al proposes a methodology to support the conceptual design of lightweight body panels for Electric Vehicles (EVs) with a combined perspective on structural integrity and Green-House-Gas (GHG) emissions.…”

Carbon Fibers Waste Recovery via Pyro-Gasification: Semi-Industrial Pilot Plant Testing and LCA

“…Further momentum toward high-performance composite recycling may also derive from policy drivers and legislation. For instance, the 2000/53/EC Directive on end-of-life vehicles (ELVs) calls for the achievement of specific recovery and recycling targets by car weight, requiring that the materials used in vehicle manufacturing could be easily retrieved [9]. As of today, most materials currently recovered during ELV shredding operations mainly include iron/steels and non-ferrous metals such as aluminum and copper.…”