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FRP E-Mobile Battery Case Concept Study. ADC A. Gillessen
FRP E-Mobile Battery Case Concept Study ADC A. Gillessen FRP E-Mobile Battery Case - Concept Study June 2013 Agenda Project Requirements C...
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FRP E-Mobile Battery Case Concept Study ADC A. Gillessen
FRP E-Mobile Battery Case - Concept Study
June 2013
Agenda
Project Requirements
Concept Development Requirements
CFK-Valley Concept
Design
Function Integration
Crash Simulation
Manufacturing Concept
Page 2 © AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
FRP E-Mobile Battery Case - Concept Study
June 2013
Project Requirements
OEM development competition
Phase I (2011)
8 weeks development time
design concept
crash simulation
manufacturing concept
[ OEM E-Mobile]
Phase II (2012)
8 weeks development time
design concept update on OEM Phase II reference design update
crash simulation for design update
manufacturing concept for design update
Page 3 © AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
[ Phase I CFK-Valley Concept & OEM Design Reference Update for Phase II]
FRP E-Mobile Battery Case - Concept Study
June 2013
Concept Development Requirements
battery Case as automotive supporting structure
maximum use of FRP light g weight g p potential
high level of function integration
obser ance of part specific req observance requirements irements
weight reduction and increased structural rigidity
demonstration of manufacturing feasibility
rate of 20 000 parts/year [ OEM Reference Design Phase I ]
Page 4 © AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
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
Page 5 © AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
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
Page 6 © AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
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
highly integrative sandwich structure
quasi-isotropic C-long-fibre ii t i C l fib stacking t ki
integrated load introduction and load transfer
service concept
crash-concept
function integration
Page 7 © AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
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
Page 8 © AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
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
Page 9 © AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
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
Page 10 © AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
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
Page 11 © AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
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
Page 12 © AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
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
Page 13 © AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
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
Page 14 © AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
corrosion protection p
FRP E-Mobile Battery Case - Concept Study
June 2013
Function Integration
TFP-Rosette
+ Metall Insert
=
Page 15 © AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
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
Page 16 © AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
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
Page 19 © AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
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
Page 20 © AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
FRP E-Mobile Battery Case - Concept Study
June 2013
Manufacturing Concept Phase II design model
manufacturing model
cross beam
body structure
composite panel
Page 21 © AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
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
64 single i l plies li application of multiaxial Material: 32 plies Æ 32 cutting steps Æ 3 stacking steps Æ 5 preforms for preforming
Page 23 © AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
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
Page 25 © AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
0° ply application
FRP E-Mobile Battery Case - Concept Study
Manufacturing Feasibility Demonstrator
Page 26 © AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
June 2013
FRP E-Mobile Battery Case - Concept Study
June 2013
© CTC GMBH. Alle Rechte vorbehalten. Vertrauliches und geschütztes Dokument. Dieses Dokument und alle darin enthaltenen Informationen sind das alleinige Eigentum der CTC GMBH. Die Zustellung dieses Dokumentes oder die Offenlegung seines Inhalts begründen keine Rechte am geistigen Eigentum. Dieses Dokument darf ohne die ausdrückliche schriftliche Genehmigung der CTC GMBH nicht vervielfältigt oder einem Dritten gegenüber enthüllt werden. Dieses Dokument und sein Inhalt dürfen nur zu bestimmungsgemäßen Zwecken verwendet werden. Die in diesem Dokument gemachten Aussagen stellen kein Angebot dar. Sie wurden auf der Grundlage der aufgeführten Annahmen und in gutem Glauben gemacht. Wenn die zugehörigen Begründungen für diese Aussagen nicht angegeben sind, ist die CTC GMBH gern bereit, deren Grundlage zu erläutern.
© CTC GMBH. All rights reserved. Confidential and proprietary document. CTC GmbH is a100% subsidiary of AIRBUS Operations GmbH
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. This document and all information contained herein is the sole property of AIRBUS S.A.S. No intellectual property rights are granted by the delivery of this document or the disclosure of its content. This document shall not be reproduced or disclosed to a third party without the express written consent of AIRBUS S.A.S. This document and its content shall not be used for any purpose other than that for which it is supplied. The statements made herein do not constitute an offer. They are based on the mentioned assumptions and are expressed in good faith. Where the supporting grounds for these statements are not shown, AIRBUS S.A.S. will be pleased to explain the basis thereof. AIRBUS, its logo, A300, A310, A318, A319, A320, A321, A330, A340, A350, A380, A400M are registered trademarks.
Page 27 © AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
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