►The entrepreneurial world: examples of efficient and sustainable solutions
“Innovative light-weight design for e-mobility”
completed projects – new approaches
Carl-Ernst Forchert, i-vector Innovationsmanagement GmbH
© i-vector Innovationsmanagement GmbH
„Greening the Corridor – New Projects, Products and Innovation“ Venice, 20.5.2014
Introduction
i-vector Innovationsmanagement GmbH
Carl-Ernst Forchert, Dipl.-Ing. Wirtschaftsingenieur,
managing director i-vector Innovationsmanagement GmbH.
Formerly he was the co-creator and initiator of the technology foresight group of INPRO
Innovationsgesellschaft für fortgeschrittene Produktionssysteme in der Fahrzeugindustrie
mbH .
i-vector Innovationsmanagement GmbH offers solutions in the field of strategic and
operational innovation management and project management of research and
development projects.
● Design an implementation of innovation management
Dipl.-Ing. Carl-Ernst Forchert
Tel.:
+49 30/225 00 321
Mobil: +49 172 399 93 22
Email: forchert@i-vector.de
● Development of environmental and technical scenarios
● Strategy development and management workshops
● Innovation roadmaps for new technologies
● Potential analysis new technologies for
►vehicle manufacturers and suppliers
►companies in the manufacturing and energy sector
© i-vector Innovationsmanagement GmbH
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„Greening the Corridor – New Projects, Products and Innovation“ Venice, 20.5.2014
Content
1. e-mobility – Windows of opportunity for new design and production technologies
2. Project A: Lightweight bodyframe for new powertrains – ebase
3. elmia subcontrctor 2013, Jönköping, Sweden, with the help of ZAB
4. Project B: Development of design concepts for lightweight solutions – SÅNÄTT
5. New horizons: Unibody vehicle platform for future commercial mobility – eSUP
© i-vector Innovationsmanagement GmbH
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„Greening the Corridor – New Projects, Products and Innovation“ Venice, 20.5.2014
Initial situation – Electric mobility

Electric mobility for maintaining individual mobility in the
focus of political interest

High expectations with regard to the availability of
electrical vehicles, Challenge: "marketable prices“
 The realization of complete vehicles is currently based
on conversion vehicles

Present development focus

Energy storage (battery technology)

Energy distribution (power electronics)

Energy conversion (electric motor)
 The specific requirements of the aggregates require
new concepts for vehicle structures, especially for the
underbody.
source: smart
© i-vector Innovationsmanagement GmbH
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„Greening the Corridor – New Projects, Products and Innovation“ Venice, 20.5.2014
Windows of opportunity for new design and production technologies
price
development needs
til 2018/20
~ 3.000
1
© i-vector Innovationsmanagement GmbH
~ 30.000
timeframe
5
50
5
100
200
amount
[1000 prod. E/a]
„Greening the Corridor – New Projects, Products and Innovation“ Venice, 20.5.2014
OBJECT BODYFRAME
Lotus Evora 414E Hybrid-Concept
source: ebase
source: heise-autos
underbody = "lower part" of the car body? Including stiffeners, axle, aggregate frames
suitable for different concepts (engine, energy generation, energy storage)
© 2014 ebase – Das Leichtbau Netzwerk
6
DEVELOPMENT GOAL

The objective of the network is the development and prototypical implementation of a new
body concept for electric vehicles.

Crash-safety designs of underbody and battery storage has priority.

Global approach for the next generation of electric vehicles:

•
function
•
security
•
weight
•
packaging.
The network partners are aiming added value in process development or in the production of
components.
© 2013 ebase – Das Leichtbau Netzwerk
7
12.06.2013
FLAMMMOTEC
•Fibre composite systems
•Automotive network
•Mediator between business and
science
•Stamped, drawn and
large stampings
•Safety parts for the
automotive industry
•Prototypes, components, tools
•Thermo and thermoset components
•Conception to implementation
•Injection moulding and pressing process
•Forms and tools
•Internal combustion engines
•Range Extender systems
•Principle solutions and concepts,
•Manufacture, testing and simulation
•Acoustics simulation FEM
•Systems for spotwelding
•Thermal simulation
•Friction Spot Welding
•platform Development
•Technical Weight Management
•3D construction
•Systematic methods for weight
loss
•Simulation and FEMA
•Electrical system development
•Robotic simulation solutions
•vehicle design
•Conception of production
engineering solutions
•Body parts and assemblies
•Implementation of system
prototypes
•dimensioning, calculations
•Interior Development
© i-vector Innovationsmanagement GmbH
•Concept development, installation studies
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•Methods-assisted technology and
innovation services
•Evaluation of future technologies
•Agile project-management
„Greening the Corridor – New Projects, Products and Innovation“ Venice, 20.5.2014
EVOLUTION OF AIRCRAFT FUSELAGE AND CARBODY
technological
evolution
aircraft body
chassis
nodes
panel
Mercedes 300SL
panel
truss
profile
belt
Audi R8 Spaceframe
frames
?
stringer
source: Bernd Klein, Leichtbaukonstruktion, VIEWEG Verlag
© 2014 ebase – Das Leichtbau Netzwerk
source: Mercedes Benz / AUDI
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LIGHT-WEIGHT BODYFRAME WITH
INTEGRATED BATTERY HOUSING
modular
battery-housing
sandwich-panel-structure
shear-field box
long-member with
integrated shear-areas
topology-optimized
nodes
3-level energy-absorber
© 2013 ebase – Das Leichtbau Netzwerk
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12.06.2013
DEVELOPMENT – STATUS 2013
OVERALL CARBODY PARAMETERS








© 2013 ebase – Das Leichtbau Netzwerk
geometry: 3700 mm x 1500 mm x 300 mm [l x w x h]
material: Al 6061
frame: sheet-metal: 2,5 mm
nodes: die cast aluminum (milled prototyping model)
shear-field: aluminum-honeycomb-sandwich 6 / 10 mm
concept weight: < 100 kg
target weight: < 80 kg
battery-capacity: 12 up to 36 KWh
IZB – Wolfsburg
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12.06.2013
FURTHER DEVELOPMENT POTENTIAL
2. Top frame
1. drive system integration
5. Integration
range-extender
4. Arrangement of
e-drive modules
6. Integration
Cockpit, Seats
© 2013 ebase – Das Leichtbau Netzwerk
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3. Load balancing, optimization
crash and nodal areas
12.06.2013
SÅNÄTT – Scandinavian development consortium
Lightweight structures in future passenger cars – project objects
Seat
● Innovative adjustment concept
● Security by vertical fixation
● Efficient air conditioning
50% weight reduction
45% weight reduction
40% weight reduction
Roof-module
● TeXtreme® Carbon Fabrics
● Modular sandwich structure
● Integration entertainment,
air conditioning
Cockpit
● fixed eye point
● Optimized minimalist operating
concept
● Driving assistance and safety
systems
50% weight reduction
Suspension-module
● Stress-orientated use of glass
fibers
● Integration: springs, stabilizer
and control arm in a leaf spring
40% weight reduction
© i-vector Innovationsmanagement GmbH
40% weight reduction
14
Door-module
● Material combination:
MuCellTM foam, aluminum
crash bars, metal glass fiber
sandwich
● Fixed window
Floor
● Upper and lower shell
forming an innovative
sandwich system
● Good shear resistance
● Room for packaging between
the shells
„Greening the CorridorBilder:
– Newwww.sanatt.se
Projects, Products and Innovation“ Venice, 20.5.2014
New horizons: Unibody Vehicle Platform for future commercial mobility
Chassis-concept, source: SÅNÄTT,
supported by Swedish government, 2010 -2013
Challenges
Reduction carbon dioxide
 Spreading of electric vehicles
 Promotion added value to developing regions
Providing new functionality for mobility related services
Competitive manufacturing processes and structures
Adaptable/modular structures designed for specific needs

Objectives


ebase - New body understructure for new propulsion systems (BEV, PHEV,…),
source: ebase, supported by BMWi, 2010 -2013


Market-pull in focus
Integration of different
innovative ideas/solutions
Competitive costs
Integration in design/
manufacturing processes
Innovation




Integrated platform design
standardized – modular –
variable
“Slow development”
Innovative assembly
technique (tough&resilent)
European Dimension


Projects started in Sweden and Germany, focus on SME
Competencies &markets in European countries involved
Further Challenges
Integration of (altern.) powertrain-components & systems
Adaption manufacturing techniques for small series
© i-vector Innovationsmanagement GmbH
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„Greening the Corridor – New Projects, Products and Innovation“ Venice, 20.5.2014
A word on Innovation
„Innovation is the implementation of a technical or organizational innovation,
not just their invention.“
Joseph Schumpeter „Theorie der wirtschaftlichen Entwicklung“, 1911
„The transformation of money into knowledge is research,
transforming knowledge into money is innovation.“
M. Mirow „Innovation als strategische Chance“, 1998
Innovation

result of many linked activities forming a chain
from the first idea until its final implementation
Key-factors

technology

economy

organization

leadership, culture
► Active control of all activities in a defined process to gain a competitive advantage
© i-vector Innovationsmanagement GmbH
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„Greening the Corridor – New Projects, Products and Innovation“ Venice, 20.5.2014
Contact
Dipl.-Ing. (FH) Wolfgang Krause
Project Management
Tel.:
Mobil:
Email:
i-vector Innovationsmanagement GmbH
Cuxhavener Straße 14
10555 Berlin
Tel.:
Fax:
Email:
+49 (0)30 22 500 320
+49 170 93 93 224
krause@i-vector.de
Dipl. -Volksw. Stefan Herzog
Corporate Development
+49 (0)30 22 500 320
+49 (0)30 22 500 329
info@i-vector.de
Tel.:
Email:
+49 (0)30 22 500 320
herzog@i-vector.de
Dipl.-Ing. Carl-Ernst Forchert
Managing Director
Tel.:
Mobil:
Email:
© i-vector Innovationsmanagement GmbH
+49 (0)30 22 500 321
+49 172 399 93 22
forchert@i-vector.de
Arne Marburg B.Sc.
Project Management
Tel.:
Email:
22
+49 (0)30 22 500 327
marburg@i-vector.de
„Greening the Corridor – New Projects, Products and Innovation“ Venice, 20.5.2014