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Automotive Product Finder Magazine | Lightweighting & battery integration are key attributes for EV body
Lightweighting & battery integration are key attributes for EV body
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In this interview, Ashok Khondge, Principal Engineer, ANSYS Customer Excellence, ANSYS Inc, explains how automakers are ensuring safety and performance of electric vehicles (EV) through the innovative methods of integration of body structures, battery packs, thermal management systems, and electric drive.
How can simulation tools help car makers to ease the process of car body designing?
While designing vehicle body, the automakers need to consider various design attributes such as structural strengths (torsion, bending strength); crashworthiness; NVH; material selection (light weighting); vehicle styling, aerodynamics, etc. Automakers have to meet targets for each of these attributes as dictated by market and regulatory pressures.
These design attributes are multi-disciplinary and conflicting in nature. A trade-off is needed to meet the final design that will satisfy all the target requirements. Automakers are using engineering simulations pervasively in all stages of vehicle development - requirement assessments, concept development and detailed design. Automakers are using integrated multi-disciplinary design optimisation methods to meet the objectives for structural strength, crashworthiness, NVH and aerodynamics. The Material Information Technology is helping design and simulation engineers to make designs with materials for all the design attributes.
How important is the right body design of the vehicle (from functional as well as styling point of view)?
Vehicle styling is associated with brand recognition – for example, distinct design of Front grille, or characteristics curves inspired by nature and more. The right body design of vehicle should strike a balance among aesthetics, ergonomics and functional requirements (dynamic stability – drag force, lift force and movements). Keeping the styling DNA, designers and engineers need to balance the functional and ergonomic attributes as well as the utility features.
How is your company helping automakers fasten the process of car body designing and development of new vehicle?
ANSYS software contains detailed, validated models, sub-models, methodologies and best-practices specifically suited for the detailed engineering needs of vehicle body design assessment. ANSYS’ comprehensive solution contains fully integrated structural, fluids, thermal and electromagnetic simulation and multi-disciplinary design optimisation tools on simulation process and data platform. ANSYS’ best practices help automakers to optimise the vehicle weight with strong and durable design, assess the crashworthiness and to optimise aerodynamics drag up-front.
What are the key features of EV body structure design?
The market share of full electric vehicle is very low - approximately 1 percent of total auto market. The internal combustion engine (ICE) vehicles are still the profit earning products for automakers. To balance the demand of ICE vehicle and EVs, automakers need to decide between designing a brand new platform for EVs and adopting the existing platforms. Underpinning electric vehicles on same ICE vehicle platform, automakers can reduce costs by commonality and economies of scales but need to compromise vehicle range, dynamic performance of vehicle, interior space and comfort.
On the other hand, the brand-new electric vehicle platform can help automakers to design electric cars with excellent range, stability, dynamics performance and very good space and comfort. However, it comes with the increase in cost associated with this new dedicated platform. For automakers, the focus is on cutting development costs while ensuring safety and performance through the innovative methods of integration of body structures, battery packs, thermal management systems, and electric drive.
In the event of crash, battery can catch the fire due to internal shorting of battery cells or penetration of objects into battery cell. Battery crash response is an important part of battery design and integration of battery pack in vehicle structure. Hence, lightweighting body structure and battery integration are key attributes for EV body structure design.
Lightweighting And Battery Integration
Thermal Management Systems
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