A Lightweight Body Frame Conceptual Design of a Mini Electric Vehicle

Abstract

To realize the lightweight structure, a car body frame conceptual design of a mini electric vehicle was performed with topology optimization and size optimization. Topology optimization was used to search load paths and size optimization was applied to model a simplified structure. Static stiffness, crash safety and free vibration conditions were considered simultaneously in both of the optimization phases. Due to the feature of conceptual design, crashworthiness cases were regarded as static stiffness ones with inertia relief analysis for a linear equivalent. The objective function in multi-objective topology optimization was defined by Compromise Programming Method in OptiStruct. Because of the characteristic of the geometry and the manufacturing constraints of profiles, the design variables in size optimization were defined as both continuous and discrete variables. The resultant structure outperforms the original one in many structure responses and most significantly, it reduces weight by 36%, which demonstrates the efficiency of the proposed method.

Review of the Fuel Saving, Life Cycle GHG Emission, and Ownership Cost Impacts of Lightweighting Vehicles with Different Powertrains

“…43,50,76 Conversely, others analyze these technologies as mutually inclusive options by only examining their combined use, which obscures the impact of each technology. 37,38,44,[46][47][48][51][52][53][71][72][73][74][75][77][78][79][80]82 Similarly, others obscure the impact of each technology by analyzing vehicle fleets comprised of a range of different vehicles and technologies. 20,25,29,33,[39][40][41][42]45 ■ FUEL SAVINGS FROM LIGHTWEIGHTING VEHICLES…”

“…Vehicle fuel savings, ,,,,,, GHG emissions, ,,,,,,,− ,,− and ownership costs (vehicle price and/or fuel costs) ,,,,,− ,,,,,,,,,− ,− are the most common metrics examined (though not always on a life cycle basis, as shown in Tables and ), and are thus the focus of this review. Less common metrics include air pollution, , life cycle energy use ,,,, or energy security, solid waste, and structural integrity. − Several articles are also limited to being a description of the design of a particular vehicle ,− or component. − …”

“…This requires an examination of these technologies as independent options (i.e., comparing lightweight and conventional weight versions of alternative powertrain vehicles, and/or alternative and conventional powertrain versions of lightweight vehicles). However, some studies treat these technologies as mutually exclusive options, by excluding their combined use. ,, Conversely, others analyze these technologies as mutually inclusive options by only examining their combined use, which obscures the impact of each technology. ,,,− ,− ,− ,− , Similarly, others obscure the impact of each technology by analyzing vehicle fleets comprised of a range of different vehicles and technologies. ,,,,− , …”

Discrete Material and Thickness Optimization of Pop-Up Seat Frame in Static Condition

“…The transport equipment manufacturing sector that largely contributes toward environmental pollution is attempting to reduce their contribution to environmental pollution through an improved fuel economy of vehicles. Studies have been conducted to reduce the weight of all automotive parts by changing their geometry, materials, and thicknesses [1][2][3]. Reducing the weight of parts is directly related to the safety of those seated in the vehicle, thereby lowering the safety performances of such parts.…”

Simulation and Lightweight Design for the Structure Frame of a Flying Car

“…The structure frame of the flying car has complex shape, large size, and various loading conditions. Jin et al [4][5] performed simulation and weight reduction analysis of the structure frame of the miniature electric car by using a combination of topology optimization and size optimization. The results show that the optimized structure is superior to the original structure and the weight of the structure frame is reduced by 36%.…”