Fang, Xiangfan
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Publication Access status: Metadata only , Elastokinematic design and optimization of the multi-link torsion axle – a novel rear axle concept for BEVs(2024); This work describes the elastokinematic design and optimization for a new, package space saving rear suspension especially intended for small battery electric vehicles. Mainly for reasons of cost and weight efficiency, the twist-beam axle is widely used, especially in the A and B segments. One of the main disadvantages of twist-beam axles is that they limit the rear package space because of the torsion profile. The basic idea of this work was to reverse the installation direction of the twist-beam axle to create an additional package space for the battery. To obtain an optimized elastokinematic design, a new algorithm was introduced that allows modeling of the elastokinematic behavior of the new mechanism. A Pareto optimization of the body connecting bushing was performed, revealing that a specific spatial orientation enables effective compensation for camber compliance deficits. Finally, the Pareto-optimized elastokinematic design was compared to compliance measurement results of a prototype vehicle equipped with the new suspension concept.Source Type:Article5 - Some of the metrics are blocked by yourconsent settings
Publication Access status: Metadata only , Evaluation of Vehicle Lateral and Longitudinal Dynamic Behavior of the New Package-Saving Multi-Link Torsion Axle (MLTA) for BEVs(2024); To increase the package space for the battery pack in the rear of battery electric vehicles (BEVs), and thus extend their driving range, a novel rear axle concept called the multi-link torsion axle (MLTA) has been developed. In this work, the kinematic design was extended with an elastokinematic concept, and the MLTA was designed in CAD and realized as a prototype. It was then integrated into a B-class series-production vehicle by ADDing masses in different locations of the vehicle to replicate the mass distribution of a BEV. Both objective and subjective vehicle dynamic evaluations were conducted, which included kinematic and compliance tests, constant-radius cornering, straight-line braking, and a frequency response test, as well as subjective evaluations by both expert and normal drivers. These test results were analyzed and compared to a production vehicle. It can be concluded that the vehicle dynamic performance of the MLTA-equipped vehicle is, overall, 0.67 grades lower than that of the comparable production vehicle on a 10-grade scale. According to OEM experts, this deficit can be eliminated by tuning the different components of the MLTA and meeting the tolerance requirements of series production vehicles.Source Type:Article1 - Some of the metrics are blocked by yourconsent settings
Publication Access status: Metadata only , Local Reinforcement of a Fuel Cell End Plate for Package Improvements Using Steel–Aluminium Hybrid-Casting TechnologyIn this research work, a method for integrating a local reinforcement structure in a medium-pressure plate (MPP) for fuel cell electric vehicle (FCEV) applications was developed using steel–aluminium hybrid-casting technology. Using this technology, it is possible to create a bonded enclosure of a steel reinforcement patch with the cast aluminium pressure plate to increase its stiffness and achieve 15% package space savings. A load-compliant, manufacturable patch was chosen and optimised for maximum stiffness gains using non-linear static finite-element (FE) calculations. Special form and process requirements due to hybrid-casting technology were examined and secured with casting simulations. The reinforcement patch was manufactured and coated with a unique aluminium–silicon coating enabling a ductile material connection between the steel and aluminium, and casting trials were conducted to create prototypes. Additionally, the insulating plastic layer on top of the metallic pressure plate carrier was substituted from costly short-fibre-reinforced high-performance plastic to cheaper and stiffer glass-mat reinforced thermoplastic material. Finally, the new hybrid MPP was tested mechanically, and the FE-Model was verified. In summary, through the package gain, 2.1 kW more power output and 11% less weight could be achieved while remaining stiffness neutral.Source Type:Article5
