Dr. Lorenzo Nicoletti

Although battery electric vehicles (BEVs) are locally emission-free and assist automakers in reducing their carbon footprint, two major disadvantages are their shorter range and higher production costs compared to combustion engines. These drawbacks are primarily due to the battery, which is generally the heaviest and most expensive component of a BEV. Lightweight measures (strategies to decrease vehicle mass, e.g., by changing materials or downsizing components) lower energy consumption and… Mehr anzeigen

Although battery electric vehicles (BEVs) are locally emission-free and assist automakers in reducing their carbon footprint, two major disadvantages are their shorter range and higher production costs compared to combustion engines. These drawbacks are primarily due to the battery, which is generally the heaviest and most expensive component of a BEV. Lightweight measures (strategies to decrease vehicle mass, e.g., by changing materials or downsizing components) lower energy consumption and reduce the amount of battery energy required (and in turn battery costs). Careful selection of lightweight measures can result in their costs being balanced out by a commensurate reduction in battery costs. This leads to a higher efficiency vehicle, but without affecting its production and development costs. In this paper, we estimate the lightweight potential of BEVs, i.e., the cost limit below which a lightweight measure is fully compensated by the cost savings it generates. We implement a parametric energy consumption and mass model and apply it to a set of BEVs. Subsequently, we apply the model to quantify the lightweight potential range (in €/kg) of BEVs. The findings of this paper can be used as a reference for the development of cheaper, lighter, and more energy-efficient BEVs. Weniger anzeigen

The modeling of battery electric vehicles (BEVs) still represents a challenge for vehicle manufacturers. The installation of the new types of components needed for BEVs gives rise to uncertainties in the quantification of parameters like the vehicle's weight. Indeed, vehicle weight plays a key role, since it has a drastic effect on the vehicle's range, which is an important selling point for BEVs. Uncertainties in weight estimation create weight fluctuations during the early development phase… Mehr anzeigen

The modeling of battery electric vehicles (BEVs) still represents a challenge for vehicle manufacturers. The installation of the new types of components needed for BEVs gives rise to uncertainties in the quantification of parameters like the vehicle's weight. Indeed, vehicle weight plays a key role, since it has a drastic effect on the vehicle's range, which is an important selling point for BEVs. Uncertainties in weight estimation create weight fluctuations during the early development phase and the need to resize components like the electric machine or battery. This in turn affects the components' volume and weight. However, such resizing can also lead to a component collision and unfeasibility of the vehicle architecture. To solve this problem and to support concept engineers during the early development phase, an iterative approach is required that is capable of estimating weight and volume fluctuations in the relevant components. The approach should also consider the geometrical interdependencies of the components, to ensure that no collisions occur between them. Taking the gearbox as an example application, this paper presents a novel approach that satisfies these requirements. Weniger anzeigen

Over recent years, the number of battery electric vehicles (BEVs) has drastically increased due to new European Union (EU) regulations. These regulations force vehicle manufacturers to adjust their product range in order to fulfill the imposed carbon dioxide limits. Such an adjustment enforces the usage of battery electric vehicles. However, research into the optimal BEV architectures and topologies is still in progress. Therefore, the aim of this paper is an analysis of all the current… Mehr anzeigen

Over recent years, the number of battery electric vehicles (BEVs) has drastically increased due to new European Union (EU) regulations. These regulations force vehicle manufacturers to adjust their product range in order to fulfill the imposed carbon dioxide limits. Such an adjustment enforces the usage of battery electric vehicles. However, research into the optimal BEV architectures and topologies is still in progress. Therefore, the aim of this paper is an analysis of all the current electric vehicle topologies. From this analysis, the authors identify different basic battery shapes. Subsequently, these shapes are used to describe the impact of the battery on the passenger compartment. As an initial result of this analysis, the authors create a new denomination method, via which it is possible to cluster the battery topologies. In a second step, the collected data is clustered using the novel denomination method. Finally, this paper presents the benchmark topologies for the analyzed segments. Weniger anzeigen

In recent years, the number of electric vehicles on the market has continuously increased. New regulations and the progressively critical effects of global warming contribute to the acceleration of this trend. Car manufacturers are obliged to redesign their fleet, gradually substituting the internal combustion vehicles with electrified vehicles. This is a complicated task, as electric powertrains still represent a new technology and no established vehicle architectures exist. To aid engineers… Mehr anzeigen

In recent years, the number of electric vehicles on the market has continuously increased. New regulations and the progressively critical effects of global warming contribute to the acceleration of this trend. Car manufacturers are obliged to redesign their fleet, gradually substituting the internal combustion vehicles with electrified vehicles. This is a complicated task, as electric powertrains still represent a new technology and no established vehicle architectures exist. To aid engineers in identifying feasible architectures in the early development phase, package tools can be employed. As in this phase, few parameters are known, such tools have to be based on empirical models. The data upon which empirical models are based must be updated cyclically. With each update, the models have to be manually recalculated, which is a time-consuming process. Therefore, this paper will propose new modeling that will enable the empirical models to update automatically. Firstly, the authors will describe the elements that make up an electric vehicle architecture. Subsequently, a database concept that enables the required data to be stored will be presented. Finally, this paper will describe the tool implementation. Weniger anzeigen

Automobile manufacturers are in the midst of the greatest phase of transformation in their history. The paradigms they used over recent decades are gradually dissolving. Two new megatrends are drastically changing the market. On the one hand, there is sustainability, which is causing the ever-increasing replacement of the combustion engine by the electric motor and is pushing the sector towards "greener" mobility. On the other hand, there is automation, which is the source of a shift towards… Mehr anzeigen

Automobile manufacturers are in the midst of the greatest phase of transformation in their history. The paradigms they used over recent decades are gradually dissolving. Two new megatrends are drastically changing the market. On the one hand, there is sustainability, which is causing the ever-increasing replacement of the combustion engine by the electric motor and is pushing the sector towards "greener" mobility. On the other hand, there is automation, which is the source of a shift towards autonomous driving. How do these megatrends affect the vehicle development process? Which potentials and changes do they cause? The answer is the key to enable vehicle manufacturers to face these changes. To answer these questions, we analyze the current development process, taking into account the individual development steps, and discuss the modifications promoted by sustainability and automation. Weniger anzeigen

Defining a vehicle concept during the early development phase is a challenging task since only a limited number of design parameters are known. For battery electric vehicles (BEVs), vehicle weight is a design parameter, which needs to be estimated by using an iterative approach, thus causing weight fluctuations during the early development phase. These weight fluctuations, in turn, require other vehicle components to be redesigned and can lead to a change in their size (secondary volume change)… Mehr anzeigen

Defining a vehicle concept during the early development phase is a challenging task since only a limited number of design parameters are known. For battery electric vehicles (BEVs), vehicle weight is a design parameter, which needs to be estimated by using an iterative approach, thus causing weight fluctuations during the early development phase. These weight fluctuations, in turn, require other vehicle components to be redesigned and can lead to a change in their size (secondary volume change) and weight (secondary weight change). Furthermore, a change in component size can impact the available installation space and can lead to a collision between components. In this paper, we focus on a component that has a high influence on the available installation space: the wheels. We model the essential components of the wheels and further quantify their secondary volume and weight changes caused by a vehicle weight fluctuation. Subsequently, we model the influence of the secondary volume changes on the available installation space at the front axle. The hereby presented approach enables an estimation of the impact of weight fluctuations on the wheels and on the available installation space, which enables a reduction in time-consuming iterations during the development process. Weniger anzeigen

The derivation of a battery electric vehicle (BEV) architecture represents a challenging task for car manufacturers. For the early development of combustion engine architectures, the required design parameters can be derived from the analysis of previously-built model series. Regarding BEV architectures, the manufacturers do not yet have a reference series of vehicles on the basis of which they can derive the essential design parameters. Therefore, these parameters are mainly estimated at high… Mehr anzeigen

The derivation of a battery electric vehicle (BEV) architecture represents a challenging task for car manufacturers. For the early development of combustion engine architectures, the required design parameters can be derived from the analysis of previously-built model series. Regarding BEV architectures, the manufacturers do not yet have a reference series of vehicles on the basis of which they can derive the essential design parameters. Therefore, these parameters are mainly estimated at high cost in the early development phase. To avoid cost-intensive changes in the further course of development it is crucial to choose the right set of design parameters. For this reason, the aim of this paper is the identification of a minimum set of design parameters, derived from the current state-of-the-art of vehicle development by a structured literature comparison. We group the results according to our definition of vehicle architecture and discuss each identified parameter to explain its relevance. The sum of all parameters presented in this paper builds a minimum set of design parameters, which can be employed as a guideline for the definition of BEV architectures in the early development stage. Weniger anzeigen

Dimensional chains are the basis for testing the feasibility of vehicle architectures in the early development phase since they allow for parametrical vehicle modeling. Parametrical modeling is employed in the early development of the vehicle in order to enable the estimation of the space available for powertrain components. For battery electric vehicles (BEVs), new dimensional chains have increased relevance because of the geometrical interdependencies between the traction battery and the… Mehr anzeigen

Dimensional chains are the basis for testing the feasibility of vehicle architectures in the early development phase since they allow for parametrical vehicle modeling. Parametrical modeling is employed in the early development of the vehicle in order to enable the estimation of the space available for powertrain components. For battery electric vehicles (BEVs), new dimensional chains have increased relevance because of the geometrical interdependencies between the traction battery and the passenger compartment. The passenger compartment and traction battery share the same position in the vehicle, i.e., between the axles, which leads to a conflict between these two components. Furthermore, the passenger compartment dimensions are needed to size components like heating, ventilation, and air conditioning (HVAC), the energy consumption of which in turn influences the required battery capacity. In order to describe these interdependencies, we identify a set of dimensional chains and derive a passenger compartment volume estimation model that can be employed in the early development phase of the vehicle design. We further analyze the single elements of the dimensional chain and present typical values for each element. Weniger anzeigen