DELIVER – Fully Electric LCV with Intelligent Body Design Features

DELIVER – Fully Electric LCV with
Intelligent Body Design Features
Strategies in Car Body Engineering 2014
Bad Nauheim, 12 March 2014
Micha Lesemann, Lutz Eckstein, Thomas Welfers
Institut für Kraftfahrzeuge (ika) – RWTH Aachen University
Micha Lesemann / Strategies in Car Body Engineering 2014
© DELIVER consortium 2014
1
Agenda
 Project Introduction
 Requirements
 DELIVER Concept
 Concept Specifications
 Drivetrain
 Body Structure
 Crash Investigation
 Derivates
 Prototype Build-up
 Summary
Micha Lesemann / Strategies in Car Body Engineering 2014
© DELIVER consortium 2014
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Project Introduction
Partners and Targets
Project consortium
Project targets
 40 % efficiency increase
 Optimised ergonomics &
loading space
 Affordable costs
 Acceptable levels of comfort
and driving performance
 Futuristic design
 Build up of a driving
demonstrator vehicle
Project duration
 Start: 11/2011
 End: 10/2014
Micha Lesemann / Strategies in Car Body Engineering 2014
© DELIVER consortium 2014
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Agenda
 Project Introduction
 Requirements
 DELIVER Concept
 Concept Specifications
 Drivetrain
 Body Structure
 Crash Investigation
 Derivates
 Prototype Build-up
 Summary
Micha Lesemann / Strategies in Car Body Engineering 2014
© DELIVER consortium 2014
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Use Cases and Requirements
 Postal service providers often execute combined deliveries
of letters and parcels
 Passenger seat frequently used as extra space for letter boxes
 Transport of passengers only occasional (70 % of the delivery
vehicles do not have any front passenger seat)
 Time pressure on delivery drivers
 Only 16 % feel free of rush [1]
 34 % that time pressure is moderate to strong stress
 Extreme time pressure experienced by every ninth driver
 Ability to ingress and egress the vehicle from both sides
favoured especially by postal delivery drivers  minimize extra
walking distances around the vehicle and hence save time [2]
 Up to 400 deliveries per day, leading to high
ergonomic loads of the driver [1]
[1] UNIROYAL [2] HBK Braunschweig, Institut für Transportation Design
Micha Lesemann / Strategies in Car Body Engineering 2014
© DELIVER consortium 2014
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Requirements for LCVs (N1)
Stress of Delivery Drivers
Days of incapacity to work per 100 employees in Germany 2011
Postal services
Waste management and recycling
Transport
Credit and insurance companies
Publisher and media
IT services
0
Muscle system and skeleton
Digestive system
Respiratory system
Circulatory system
500
1000
1500
2000
Injuries / intoxication
Mental disorders
[Source: BKK Gesundheitsreport 2012]
Others
Employees of postal service providers suffer comparatively often from
incapacity to work due to diseases in the muscle system and skeleton.
Micha Lesemann / Strategies in Car Body Engineering 2014
© DELIVER consortium 2014
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Agenda
 Project Introduction
 Requirements
 DELIVER Concept
 Concept Specifications
 Drivetrain
 Body Structure
 Crash Investigation
 Derivates
 Prototype Build-up
 Summary
Micha Lesemann / Strategies in Car Body Engineering 2014
© DELIVER consortium 2014
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DELIVER Concept
Concept Specifications
Targets
Micha Lesemann / Strategies in Car Body Engineering 2014
 GVW:
2,200 kg
 Payload mass:
min. 700 kg
 Payload volume:
min. 4 m3
 Max. speed:
100 km/h
 Propulsion:
2 wheel drive (rear)
 Range:
min. 100 km (half laden)
 Length:
4,500 mm
 Width:
1,800 mm
 Height:
2,000 mm
 Seats:
1+1
© DELIVER consortium 2014
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DELIVER Concept
Drivetrain
Battery specifications
Motor specifications

Max. torque
42 Nm

Max. power
57 kW

Max. motor speed
13,600 min-1

Voltage
375 V (DC)

Gear ratio
i1: 26.057 : 1
i2: 14.545 : 1
Micha Lesemann / Strategies in Car Body Engineering 2014

80 prismatic Li-NMC cells

BMS (hard- and software) custom made

Energy content
21.6 kWh

Peak power supply
96 kW

Range of voltage
230 - 336 V (DC)
© DELIVER consortium 2014
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DELIVER Concept
Drivetrain
Vehicle performances @ 100 % SOC
vmax
0 - vmax
0 - 100 km/h
50 - 80 km/h
Take-off speed after 2 sec.
Minimal motor torque for a gradeability of 20 %
Gradeability
Range in NEDC
Kerb weight (1,500 kg)
GVW (2,200 kg)
112 km/h
13,4 s
10,3 s
3,5 s
30 km/h
18,5 Nm
st
1 gear: 51 % / 2nd gear : 26 %
-
112 km/h
19,9 s
15,4 s
5,2 s
21 km/h
26,8 Nm
st
1 gear: 32 % / 2nd gear: 17 %
135 km
40
1050
30
700
20
350
10
0
0
0
10
20
30
40 50 60 70 80
Vehicle Speed [km/h]
Micha Lesemann / Strategies in Car Body Engineering 2014
Power on wheel [kW]
Gear ratio [-]
Torque on wheel [Nm]
rpm * 10
Torque & Power on Wheel
1400
rpm * 10
T wheel 2th
T wheel 1+2th
Soft limitation
Gear ratio
P Wheel 1+2th
90 100 110
© DELIVER consortium 2014
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DELIVER Concept
Body Structure
Architecture
1. Space frame
2. Self supporting
3. Ladder frame
Function
+
○
-
Material
Cost
+
+
○
Total
+
○
-
Influencing factors
 High amount of stiffness already provided
by sandwich floor construction with
longitudinals in two different planes
HSS
(20MnB5)
Steel
(HC220B)
Aluminum
(AlMgSi1)
CFRP
(EP-CF 65)
Lightweight
Environment
Cost
Total
○
+
○
+
-
+
+
○
+
○
○
○
+
-
-
-
Current structure
 High weighting factor for “lightweight”
criterion due to project targets
 High weighting factor for “cost” criterion
due to importance for commercial vehicles
 Consideration of total energy balance
(with energy required for material
production) included in “environment”
criterion
Micha Lesemann / Strategies in Car Body Engineering 2014
© DELIVER consortium 2014
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DELIVER Concept
Crash Investigation
First optimisation loop
Critical load cases with regard to driver
safety and battery protection
FMVSS 208
 Euro NCAP ODB
Euro NCAP Pole
FMVSS 301
ECE R 95
Euro NCAP ODB
Critical load cases
(1st optimisation loop)
Micha Lesemann / Strategies in Car Body Engineering 2014
© DELIVER consortium 2014
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DELIVER Concept
Crash Investigation
 FMVSS 208
Micha Lesemann / Strategies in Car Body Engineering 2014
 Euro NCAP Pole
© DELIVER consortium 2014
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DELIVER Concept
Derivates
Use case analysis
Ideation sketches
Definition of five vehicles derivates with two different wheelbases
short
long
Transporter
x
x
Bus
x
x
Pick up
x
x
Flat bed
x
Box
x
Micha Lesemann / Strategies in Car Body Engineering 2014
© DELIVER consortium 2014
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DELIVER Concept
8 Derivates with 5 Structure Modules
Short wheelbase
Base structure
Closed module
Micha Lesemann / Strategies in Car Body Engineering 2014
Long wheelbase
Base structure
Closed module
Box module
© DELIVER consortium 2014
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DELIVER Concept
Upper Bodies
Long
Box
module
Closed
module
Base
structure
Short
Not considered
Micha Lesemann / Strategies in Car Body Engineering 2014
© DELIVER consortium 2014
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Agenda
 Project Introduction
 Requirements
 DELIVER Concept
 Concept Specifications
 Drivetrain
 Body Structure
 Crash Investigation
 Derivates
 Prototype Build-up
 Summary
Micha Lesemann / Strategies in Car Body Engineering 2014
© DELIVER consortium 2014
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Prototype Build-up
Battery Commissioning in Aachen
Upper Body Build-up at HPLP
Video
Micha Lesemann / Strategies in Car Body Engineering 2014
© DELIVER consortium 2014
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Prototype Build-up
Micha Lesemann / Strategies in Car Body Engineering 2014
© DELIVER consortium 2014
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Agenda
 Project Introduction
 Requirements
 DELIVER Concept
 Concept Specifications
 Drivetrain
 Body Structure
 Crash Investigation
 Derivates
 Prototype Build-up
 Summary
Micha Lesemann / Strategies in Car Body Engineering 2014
© DELIVER consortium 2014
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Summary and Outlook
 Delivery drivers exposed to extreme time pressure and high ergonomic workload
high numbers of sick leaves
 DELIVER is innovative vehicle concept with important features
 Fully electric drive train with in-wheel motors increasing energy efficiency
 Flexible ergonomic cabin concept contributing in decreasing the workload of delivery
drivers and the duration of the delivery process itself
 First loop of crash investigations promising, but improvements required
 Outlook
 Completion of physical demonstrator vehicle in April 2014
 Physical assessment (testing on roller benches and test tracks) with regard to
measuring real consumption, noise emissions, electromagnetic compatibility and
ergonomics improvements
 Virtual assessment in order to quantify lightweight potential etc.
 DELIVER project will be finalised in October 2014
Micha Lesemann / Strategies in Car Body Engineering 2014
© DELIVER consortium 2014
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Thank you for your attention!
Dipl.-Ing. Micha Lesemann
Institut für Kraftfahrzeuge (ika)
RWTH Aachen University
Steinbachstraße 7, 52074 Aachen
Germany
Phone
Fax
E-Mail
Internet
+49 241 80 27535
+49 241 80 22147
[email protected]
www.deliver-project.org
Micha Lesemann / Strategies in Car Body Engineering 2014
The research leading to these results has received funding from the
European Community's Seventh Framework Programme (FP7/20072013) under grant agreement no. 285296. This publication solely
reflects the authors’ views. The European Community is not liable for
any use that may be made of the information contained herein.
© DELIVER consortium 2014
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