FRP E-Mobile Battery Case Concept Study ADC A. Gillessen

FRP E-Mobile Battery Case - Concept Study

June 2013

Agenda

ƒ

Project Requirements

ƒ

Concept Development Requirements

ƒ

CFK-Valley Concept ƒ

Design

ƒ

Function Integration

ƒ

Crash Simulation

ƒ

Manufacturing Concept

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FRP E-Mobile Battery Case - Concept Study

June 2013

Project Requirements ƒ

OEM development competition

ƒ

Phase I (2011)

ƒ

ƒ

8 weeks development time

ƒ

design concept

ƒ

crash simulation

ƒ

manufacturing concept

[ OEM E-Mobile]

Phase II (2012) ƒ

8 weeks development time

ƒ

design concept update on OEM Phase II reference design update

ƒ

crash simulation for design update

ƒ

manufacturing concept for design update

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[ Phase I CFK-Valley Concept & OEM Design Reference Update for Phase II]

FRP E-Mobile Battery Case - Concept Study

June 2013

Concept Development Requirements

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battery Case as automotive supporting structure

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maximum use of FRP light g weight g p potential

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high level of function integration

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obser ance of part specific req observance requirements irements

ƒ

weight reduction and increased structural rigidity

ƒ

demonstration of manufacturing feasibility

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rate of 20 000 parts/year [ OEM Reference Design Phase I ]

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FRP E-Mobile Battery Case - Concept Study

June 2013

Development Team

Alexander Gillessen

Frank Goetz

Nicolas Meyer

René Jäkel

Christian Lair

Oliver Preuß

Carsten Rowedder

Ralf Meyer

Martin Wachtel

Mohamed Sayeh

Helge von Selasinsky

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FRP E-Mobile Battery Case - Concept Study

June 2013

CAE-Chain CFK-Valley

Manufacturing CATIA V5 CPM & MS Visio

Sim lation Simulation

Design

Abaqus & Composites Link

Composite Modul

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FRP E-Mobile Battery Case - Concept Study

June 2013

Phase I & Phase II Concept Highly integrative 2-part Concept

Phase I Concept

Phase II Concept

winner concept of competition phase I Integral RTM Body-Structure

SMC-Cover

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highly integrative sandwich structure

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quasi-isotropic C-long-fibre ii t i C l fib stacking t ki

ƒ

integrated load introduction and load transfer

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service concept

ƒ

crash-concept

ƒ

function integration

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FRP E-Mobile Battery Case - Concept Study

June 2013

Design Phase I body structure

composite panel

composite frame

CFRP

foam core

cross beam

CFRP

foam core

cross beam longitudinal beam

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FRP E-Mobile Battery Case - Concept Study

June 2013

Design Phase I body structure

composite panel

composite frame

CFRP

foam core longitudinal beam

monolithic CFRP

foam core panel

foam core cross beam

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Sandwich

monolithic CFRP = cross beam replacement

FRP E-Mobile Battery Case - Concept Study

June 2013

Weight Reduction Phase I metal panel

+

steel frame Reference Design

Density = 3,58 kg/dm³

33 kg + 20 kg = 53 kg

25 kg CFK-Valley Concept Body Structure

composite panel

+

composite frame - 37 kg g

- 13 kg g

- 68 %

- 50 %

Density = 1,9 kg/dm³

11 kg + 5 kg = 16 kg

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12 kg

FRP E-Mobile Battery Case - Concept Study

June 2013

Design Phase II B-B

1

Phase I body structure 2

Phase II body structure 1. 2.

3

3.

contoured foam core = circumferential beam Phase I replacement

Reduced number of cross beams Integrated circumferential beam Pure Sandwich panel

B-B

Integrated 0 plies

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FRP E-Mobile Battery Case - Concept Study

June 2013

Design Phase II

+

foam core with C C-Fibre Fibre cover plies

upper cross beam SMC Caps

monolithic area sandwich panel cover plies

foam core

Cross Beam

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lower cross beam

FRP E-Mobile Battery Case - Concept Study

June 2013

Weight Reduction Phase II metal panel

+

metal reinforcement Reference Design

Density = 2,0 kg/dm³

18 kg + 18 kg = 36 kg

13 kg CFK-Valley Concept Body Structure

composite panel - 14 kg g

- 2 kg g

- 39 %

- 15 %

Density = 1,7 kg/dm³

22 kg

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11 kg

FRP E-Mobile Battery Case - Concept Study

June 2013

Function Integration battery module

foam core

battery case b tt temperature control battery module fitting

temperature e pe a u e co control o

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corrosion protection p

FRP E-Mobile Battery Case - Concept Study

June 2013

Function Integration

TFP-Rosette

+ Metall Insert

=

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Maintenance Hatch Battery

FRP E-Mobile Battery Case - Concept Study

June 2013

Crash Simulation Phase I

2 Video Phase II.avi avi 2_Video_Phase

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FRP E-Mobile Battery Case - Concept Study

Crash Simulation Phase II

3 Video Phase II.avi II avi 3_Video_Phase

© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.

June 2013

FRP E-Mobile Battery Case - Concept Study

Crash Simulation Phase II

4 Video Phase II.avi II avi 4_Video_Phase

© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.

June 2013

FRP E-Mobile Battery Case - Concept Study

Crash Simulation Phase II

5 Video Phase II.avi II avi 5_Video_Phase

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June 2013

FRP E-Mobile Battery Case - Concept Study

June 2013

Manufacturing Concept Phase I design model

manufacturing model

composite frame

body structure

composite panel

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FRP E-Mobile Battery Case - Concept Study

June 2013

Manufacturing Concept Phase II design model

manufacturing model

cross beam

body structure

composite panel

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FRP E-Mobile Battery Case - Concept Study

June 2013

Manufacturing Process Concept Pre-Process

Sub-Preforming

Preforming

Curing

Cutting

Handling

HP RTM HP-RTM

Stacking

Handling

Auto-RTM

Net-Shape Core

UD Braided Cross Beam

SMC End-Caps

Process Chain Page 22 © AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.

FRP E-Mobile Battery Case - Concept Study

Manufacturing Concept

ƒ 64 single i l plies li ƒ application of multiaxial Material: 32 plies Æ 32 cutting steps Æ 3 stacking steps Æ 5 preforms for preforming

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June 2013

FRP E-Mobile Battery Case - Concept Study

June 2013

Manufacturing 90°

+ 45° 0° - 45°

sandwich panel

foam core handling g device Page 24 © AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.

NCF handling g device

FRP E-Mobile Battery Case - Concept Study

June 2013

Manufacturing

+/-° ply application

UD Braiding

Cross Beam

Industrial Scenario

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0° ply application

FRP E-Mobile Battery Case - Concept Study

Manufacturing Feasibility Demonstrator

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June 2013

FRP E-Mobile Battery Case - Concept Study

June 2013

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