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FRP E-Mobile Battery CaseConcept Study

ADCA. Gillessen

AgendaJune 2013FRP E-Mobile Battery Case - Concept Study

Project Requirements

Concept Development Requirements

CFK-Valley Concept

Design

Function Integration

Crash SimulationCrash Simulation

Manufacturing Concept

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

Project RequirementsJune 2013FRP E-Mobile Battery Case - Concept Study

OEM development competition

Phase I (2011)

8 weeks development time

design concept

crash simulation

manufacturing concept

[ OEM E-Mobile]

manufacturing concept

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

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


Concept Development RequirementsJune 2013FRP E-Mobile Battery Case - Concept Study

battery Case as automotive supporting structure

maximum use of FRP light weight potentialg g p

high level of function integration

obser ance of part specific req irementsobservance of part specific requirements

weight reduction and increased structural rigidity

demonstration of manufacturing feasibility

rate of 20 000 parts/year

[ OEM Reference Design Phase I ]


Development TeamJune 2013FRP E-Mobile Battery Case - Concept Study

Frank Goetz

Christian Lair

Nicolas Meyer

Oliver Preuß

Alexander Gillessen

René Jäkel

Ralf Meyer Martin WachtelCarsten Rowedder

Mohamed Sayeh

Helge von Selasinsky


CAE-Chain CFK-ValleyJune 2013FRP E-Mobile Battery Case - Concept Study

ManufacturingCATIA V5 CPM & MS Visio

ManufacturingCATIA V5 CPM & MS Visio

Sim lationSim lation DesignDesignSimulationAbaqus & Composites Link

SimulationAbaqus & Composites Link

DesignComposite Modul

DesignComposite Modul


Phase I & Phase II ConceptJune 2013FRP E-Mobile Battery Case - Concept Study

Highly integrative 2-part Concept

Phase I Concept Phase II Concept

Integral RTM Body-Structure

highly integrative sandwich structure

SMC-Cover

i i t i C l fib t ki

winner concept of competition phase I

highly integrative sandwich structure

integrated load introduction and load transfer

crash-concept

function integration

quasi-isotropic C-long-fibre stacking

service concept


function integration

Design Phase IJune 2013FRP E-Mobile Battery Case - Concept Study

body structurebody structure

composite framecomposite panel

foam core CFRPcross beamCFRP

foam core

longitudinal beam

cross beam


Design Phase IJune 2013FRP E-Mobile Battery Case - Concept Study

body structurebody structure

composite framecomposite panel

foam corelongitudinal beam

CFRP

foam corepanel

monolithic CFRP foam core

cross beam

monolithic CFRP=

cross beam replacementSandwich


Weight Reduction Phase IJune 2013FRP E-Mobile Battery Case - Concept Study

+ steel framemetal panel

Reference Design

33 kg + 20 kg = 53 kgDensity = 3,58 kg/dm³

25 kg

+ composite framecomposite panel- 37 kg - 13 kg

CFK-Valley Concept Body Structure

g

- 68 %

g

- 50 %

11 kg + 5 kg = 16 kg

Density = 1,9 kg/dm³

12 kg


June 2013FRP E-Mobile Battery Case - Concept Study

Design Phase IIB-B

1

contoured foam core =

Phase I body structure Phase II body structure circumferential beam Phase I replacement

2 1. Reduced number of cross beams

3

2. Integrated circumferential beam

3. Pure Sandwich panel

Integrated 0 plies

B-B



Design Phase II

foam core with C Fibre

+SMC Caps

upper cross beam

foam core with C-Fibre cover plies

monolithic

lower cross beamsandwich panel

cover plies

area

Cross Beamfoam core


Weight Reduction Phase IIJune 2013FRP E-Mobile Battery Case - Concept Study

+ metal reinforcementmetal panel

Reference Design

18 kg + 18 kg = 36 kgDensity = 2,0 kg/dm³

13 kg

composite panel- 14 kg - 2 kg

CFK-Valley Concept Body Structure

g

- 39 %

g

- 15 %

22 kg

Density = 1,7 kg/dm³

11 kg


Function IntegrationJune 2013FRP E-Mobile Battery Case - Concept Study

battery module

b ttfoam core

battery casetemperature control

battery module fitting corrosion protectionp

temperature control


e pe a u e co o


Function Integration

TFP-Rosette

+Battery

Maintenance Hatch

Metall InsertMetall Insert

=


Crash Simulation Phase IJune 2013FRP E-Mobile Battery Case - Concept Study

2 Video Phase I avi


2_Video_Phase I.avi


Crash Simulation Phase II

3 Video Phase II avi


3_Video_Phase II.avi

Manufacturing Concept Phase IJune 2013FRP E-Mobile Battery Case - Concept Study

design model manufacturing model

composite frame

body structure

composite panel


Manufacturing Concept Phase IIJune 2013FRP E-Mobile Battery Case - Concept Study

design model manufacturing model

cross beam

body structure

composite panel


Manufacturing Process ConceptJune 2013FRP E-Mobile Battery Case - Concept Study

Pre-Process Sub-Preforming Preforming Curing

Net-Shape CoreNet-Shape Core

CuttingCutting HandlingHandling HP-RTMHP-RTMCuttingCutting HandlingHandling HP RTMHP RTM

UD Braided Cross BeamUD Braided Cross Beam

Process Chain

SMC End-CapsSMC End-Caps StackingStacking HandlingHandling Auto-RTMAuto-RTM


Process Chain

Manufacturing ConceptJune 2013FRP E-Mobile Battery Case - Concept Study

64 i l li64 single plies

application of multiaxialMaterial:

32 plies

32 cutting steps

3 stacking steps

5 preforms for preforming


ManufacturingJune 2013FRP E-Mobile Battery Case - Concept Study

90° + 45°

0°

- 45°

sandwich panel

foam core handling device NCF handling device


g g

ManufacturingJune 2013FRP E-Mobile Battery Case - Concept Study

UD Braiding 0° ply application+/-° ply application

Cross Beam

Industrial Scenario


Manufacturing Feasibility DemonstratorJune 2013FRP E-Mobile Battery Case - Concept Study



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