Carbon fiber monocoque for a hydrogen prototype for low consumption challenge

Airale, Andrea Giancarlo; Carello, Massimiliana; Scattina, Alessandro

doi:10.1002/mawe.201100793

Cited by 29 publications

(11 citation statements)

References 8 publications

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“…Furthermore, an example of an aluminum space frame chassis is presented in bibliography [12]. Also, hydrogen fuel cell powered car's chassis for Shell Eco Marathon is found in work [13]. Obviously, the need for lower conceptual design costs in shorter time in conjunction with the need for new modeling techniques, lead the automotive companies to find better ways to develop vehicles.…”

Section: Vehicle and Chassis Design And Specificationsmentioning

confidence: 99%

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Electric Car Chassis for Shell Eco Marathon Competition: Design, Modelling and Finite Element Analysis

Tsirogiannis

Stavroulakis

Makridis

2019

WEVJ

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The increasing demand for energy efficient electric cars, in the automotive sector, entails the need for improvement of their structures, especially the chassis, because of its multifaceted role on the vehicle dynamic behaviour. The major criteria for the development of electric car chassis are the stiffness and strength enhancement subject to mass reduction as well as cost and time elimination. Towards this direction, this work indicates an integrated methodology of developing an electric car chassis considering the modeling and simulation concurrently. The chassis has been designed in compliance with the regulations of Shell Eco Marathon competition. This methodology is implemented both by the use of our chassis load calculator (CLC) model, which automatically calculates the total loads applied on the vehicle’s chassis and by the determination of a worst case stress scenario. Under this extreme stress scenario, the model’s output was evaluated for the chassis design and the FEA method was performed by the pre-processor ANSA and the solver Ansys. This method could be characterized as an accurate ultrafast and cost-efficient method.

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Section: Vehicle and Chassis Design And Specificationsmentioning

confidence: 99%

“…Furthermore, an example of an aluminum space frame chassis is presented in bibliography [12]. Also, hydrogen fuel cell powered car's chassis for Shell Eco Marathon is found in work [13].…”

Section: Introductionmentioning

confidence: 99%

Electric Car Chassis for Shell Eco Marathon Competition: Design, Modelling and Finite Element Analysis

Tsirogiannis

Stavroulakis

Makridis

2019

WEVJ

View full text Add to dashboard Cite

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“…The NTHS was tested and optimized in HySy-Lab laboratory and afterwards implemented on the vehicle prototype IDRA [12,24] that participated at the Shell Eco-Marathon competition [25] (Rotterdam-May 2015) achieving good results in terms of consumption. IDRA [26][27][28] (Figure 6a) is a carbon-fiber monocoque prototype [29,30] of 38 kg, 3 m length, 0.6 m height and 0.95 m width. The FCEV has a 200 W brushed electric motor and a 1 kW [31] closed cathode FC (Figure 6b) supplied, through a pressure reducer, by a 0.4 L at 200 bar hydrogen cylinder .…”

Section: Application and Operation Conditionsmentioning

confidence: 99%

Nafion® Tubing Humidification System for Polymer Electrolyte Membrane Fuel Cells

et al. 2019

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Humidity and temperature have an essential influence on PEM fuel cell system performance. The water content within the polymeric membrane is important for enhancing proton conduction and achieving high efficiency of the system. The combination of non-stationary operation requests and the variability of environment conditions poses an important challenge to maintaining optimal membrane hydration. This paper presents a humidification and thermal control system, to prevent the membrane from drying. The main characteristics of such a device are small size and weight, compactness and robustness, easy implementation on commercial fuel cell, and low power consumption. In particular, the NTHS method was studied in a theoretical approach, tested and optimized in a laboratory and finally applied to a PEMFC of 1 kW that supplied energy for the prototype vehicle IDRA at the Shell Eco-Marathon competition. Using a specific electronic board, which controls several variables and decides the optimal reaction air flow rate, the NTHS was managed. Furthermore, the effects of membrane drying and electrode flooding were presented.

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“…Examples of electric cars with space frame chassis are found in literature for racing car [11] and for autonomous guided vehicle [12]. In addition, chassis designs for fuel cell powered cars suitable for Shell Eco Marathon have developed in previous works using carbon-fiber monocoque type [13] and carbon-fiber monocoque type reinforced with honeycomb [14].…”

Section: Introductionmentioning

confidence: 99%

Lightweight Design and Welding Manufacturing of a Hydrogen Fuel Cell Powered Car’s Chassis

et al. 2018

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The development of the chassis for the hydrogen fuel cell powered car has been involved in the designing and manufacturing aspects, while taking into consideration the mass, strength, stiffness, centre of gravity (COG), and manufacturing cost requirements. Towards this direction, a chassis design is proposed employing a space frame structure and constructed by an aluminium alloy with great strength. The structural design has been derived through the lightweight engineering approaches in conjunction with the part consolidation, Design for Assembly (DFA) and Design for Manufacture methods. Moreover, it has been performed in compliance with the safety regulations of the Shell Eco Marathon racing competition. The material's principal characteristics are the great strength, the low mass, as well as the great workability, machinability, and weldability. Following the national and global environmental issues, the recyclable characteristics of the aluminium alloy are an extra asset. Furthermore, the existence of aluminium alloy manufacturers around the fabricating area provides low cost supply and fast delivery benefits. The integration of the fuel cell powered vehicle is obtained through the designing and the manufacturing processes of the chassis and the parts fitted on the chassis. The manufacturing procedures are described thoroughly; mainly consisting of the cutting and welding processes and the assembling of the parts that are fitted on the chassis. Additionally, the proper welding parameters for the custom chassis design are investigated and are selected after deductive reasoning. The quality control of the weld joints is conducted by non-destructive methods (NDT) ensuring the required structural properties of the welds. A combination of the selected material, the specific type of the chassis, and the manufacturing processes lead to construction simplicity in a low manufacturing cost by using the existing laboratory equipment. Furthermore, the designing and manufacturing parameters lead to a stiff with a low centre of gravity, and the most lightweight chassis of the urban concept category at the Shell Eco Marathon race.

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Carbon fiber monocoque for a hydrogen prototype for low consumption challenge

Cited by 29 publications

References 8 publications

Electric Car Chassis for Shell Eco Marathon Competition: Design, Modelling and Finite Element Analysis

Electric Car Chassis for Shell Eco Marathon Competition: Design, Modelling and Finite Element Analysis

Nafion® Tubing Humidification System for Polymer Electrolyte Membrane Fuel Cells

Lightweight Design and Welding Manufacturing of a Hydrogen Fuel Cell Powered Car’s Chassis

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