The Design and Manufacturing Process of an Electric Sport Car (EVT S1) Chassis
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RESEARCH PAPER
The Design and Manufacturing Process of an Electric Sport Car (EVT S1) Chassis Volkan Parlaktaş1 · Engin Tanık1 · Nahit Babaarslan2 · Göktuğ Burak Çalık3 Received: 9 January 2018 / Accepted: 21 October 2019 © Shiraz University 2019
Abstract Nowadays, electric vehicles are becoming more popular day by day. Prototypes of such vehicles are being built extensively; however, cost of them is usually very high. This study presents novel approaches for design and manufacturing of an electric vehicle chassis and its fixtures with very low cost. The chassis is tub type and its original structure is formed regarding manufacturing simplicity, lightness, robustness, and low cost. This novel chassis is formed by planar and simple aluminum profiles that are readily available in stocks of producers. The design philosophy of the chassis is discussed in detail. Finite element analyses of the chassis are adopted for various crash impact loading scenarios and torsional rigidity. Also, original fixture designs for low-cost manufacturing are introduced in this study. Manufacturing cost of the chassis, fixtures, and the vehicle is presented. After road tests, the results are presented and discussed. It is evidenced that a lightweight and low-cost chassis built from simple planar parts may perform very well. Electric vehicles possessing such simple and robust chassis may be popular due to the manufacturing advantages against today’s extremely complex designs. Keywords Chassis design · Chassis fixture · Crashworthiness · Electric vehicle · Finite element analysis
1 Introduction Electric vehicles (EVs) are becoming popular because of the high fossil fuel prices and strict emission rules (Chan and Chau 1997; Xiang et al. 2017). However, even lithiumbased batteries possess a relatively low specific energy; therefore, heavy vehicles require a large quantity of batteries (Rao et al. 2014; Cui and Zhang 2015; Baek et al. 2015). Moreover, lithium-based batteries are still pricey; therefore, EVs cannot compete with internal combustion engine vehicles (ICEVs) when cost is taken into account (Chan 2002). Today’s mid-sized electric cars sold on the market weigh around 1500 kg, and approximately one-fifth of their weight consists of batteries (Burke 2007). An EV should be as light in weight as possible and streamlined; with its * Volkan Parlaktaş [email protected] 1
Department of Mechanical Engineering, Hacettepe University Beytepe, 06800 Çankaya, Ankara, Turkey
2
Nurol Makina ve Sanayi A.Ş., Avrupa Hun Cad, No. 6 Sincan Org. San. Bölgesi, Ankara, Turkey
3
FNSS Savunma Sistemleri A.Ş., Oğulbey Mah. Kumludere Cad. No. 11 Gölbaşı, Ankara, Turkey
body optimized for minimum drag, optimized for minimum rolling resistance from its tires, brakes, and steering, and optimized for minimum drive train losses. It is obvious that as an EV becomes lighter, energy requirement decreases for the same range; therefore, cost of the EV is reduced significantly, because less quantity of battery is required (Tanık and Parlaktaş 201
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