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FRP E-Mobile Battery CaseConcept Study
ADCA. Gillessen
AgendaJune 2013FRP E-Mobile Battery Case - Concept Study
Project Requirements
Concept Development Requirements
CFK-Valley Concept
Design
Function Integration
Crash SimulationCrash Simulation
Manufacturing Concept
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
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Project RequirementsJune 2013FRP E-Mobile Battery Case - Concept Study
OEM development competition
Phase I (2011)
8 weeks development time
design concept
crash simulation
manufacturing concept
[ OEM E-Mobile]
manufacturing concept
Phase II (2012)
8 weeks development time
design concept update on OEM Phase II
reference design update
crash simulation for design update
manufacturing concept for design update
[ Phase I CFK-Valley Concept & OEM Design Reference Update for Phase II]
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
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Concept Development RequirementsJune 2013FRP E-Mobile Battery Case - Concept Study
battery Case as automotive supporting structure
maximum use of FRP light weight potentialg g p
high level of function integration
obser ance of part specific req irementsobservance of part specific requirements
weight reduction and increased structural rigidity
demonstration of manufacturing feasibility
rate of 20 000 parts/year
[ OEM Reference Design Phase I ]
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
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Development TeamJune 2013FRP E-Mobile Battery Case - Concept Study
Frank Goetz
Christian Lair
Nicolas Meyer
Oliver Preuß
Alexander Gillessen
René Jäkel
Ralf Meyer Martin WachtelCarsten Rowedder
Mohamed Sayeh
Helge von Selasinsky
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
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CAE-Chain CFK-ValleyJune 2013FRP E-Mobile Battery Case - Concept Study
ManufacturingCATIA V5 CPM & MS Visio
ManufacturingCATIA V5 CPM & MS Visio
Sim lationSim lation DesignDesignSimulationAbaqus & Composites Link
SimulationAbaqus & Composites Link
DesignComposite Modul
DesignComposite Modul
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
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Phase I & Phase II ConceptJune 2013FRP E-Mobile Battery Case - Concept Study
Highly integrative 2-part Concept
Phase I Concept Phase II Concept
Integral RTM Body-Structure
highly integrative sandwich structure
SMC-Cover
i i t i C l fib t ki
winner concept of competition phase I
highly integrative sandwich structure
integrated load introduction and load transfer
crash-concept
function integration
quasi-isotropic C-long-fibre stacking
service concept
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
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function integration
Design Phase IJune 2013FRP E-Mobile Battery Case - Concept Study
body structurebody structure
composite framecomposite panel
foam core CFRPcross beamCFRP
foam core
longitudinal beam
cross beam
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
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Design Phase IJune 2013FRP E-Mobile Battery Case - Concept Study
body structurebody structure
composite framecomposite panel
foam corelongitudinal beam
CFRP
foam corepanel
monolithic CFRP foam core
cross beam
monolithic CFRP=
cross beam replacementSandwich
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
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Weight Reduction Phase IJune 2013FRP E-Mobile Battery Case - Concept Study
+ steel framemetal panel
Reference Design
33 kg + 20 kg = 53 kgDensity = 3,58 kg/dm³
25 kg
+ composite framecomposite panel- 37 kg - 13 kg
CFK-Valley Concept Body Structure
g
- 68 %
g
- 50 %
11 kg + 5 kg = 16 kg
Density = 1,9 kg/dm³
12 kg
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
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June 2013FRP E-Mobile Battery Case - Concept Study
Design Phase IIB-B
1
contoured foam core =
Phase I body structure Phase II body structure circumferential beam Phase I replacement
2 1. Reduced number of cross beams
3
2. Integrated circumferential beam
3. Pure Sandwich panel
Integrated 0 plies
B-B
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
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June 2013FRP E-Mobile Battery Case - Concept Study
Design Phase II
foam core with C Fibre
+SMC Caps
upper cross beam
foam core with C-Fibre cover plies
monolithic
lower cross beamsandwich panel
cover plies
area
Cross Beamfoam core
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
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Weight Reduction Phase IIJune 2013FRP E-Mobile Battery Case - Concept Study
+ metal reinforcementmetal panel
Reference Design
18 kg + 18 kg = 36 kgDensity = 2,0 kg/dm³
13 kg
composite panel- 14 kg - 2 kg
CFK-Valley Concept Body Structure
g
- 39 %
g
- 15 %
22 kg
Density = 1,7 kg/dm³
11 kg
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
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Function IntegrationJune 2013FRP E-Mobile Battery Case - Concept Study
battery module
b ttfoam core
battery casetemperature control
battery module fitting corrosion protectionp
temperature control
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
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e pe a u e co o
June 2013FRP E-Mobile Battery Case - Concept Study
Function Integration
TFP-Rosette
+Battery
Maintenance Hatch
Metall InsertMetall Insert
=
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
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Crash Simulation Phase IJune 2013FRP E-Mobile Battery Case - Concept Study
2 Video Phase I avi
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
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2_Video_Phase I.avi
June 2013FRP E-Mobile Battery Case - Concept Study
Crash Simulation Phase II
3 Video Phase II avi
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
3_Video_Phase II.avi
June 2013FRP E-Mobile Battery Case - Concept Study
Crash Simulation Phase II
4 Video Phase II avi
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
4_Video_Phase II.avi
June 2013FRP E-Mobile Battery Case - Concept Study
Crash Simulation Phase II
5 Video Phase II avi
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
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5_Video_Phase II.avi
Manufacturing Concept Phase IJune 2013FRP E-Mobile Battery Case - Concept Study
design model manufacturing model
composite frame
body structure
composite panel
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
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Manufacturing Concept Phase IIJune 2013FRP E-Mobile Battery Case - Concept Study
design model manufacturing model
cross beam
body structure
composite panel
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
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Manufacturing Process ConceptJune 2013FRP E-Mobile Battery Case - Concept Study
Pre-Process Sub-Preforming Preforming Curing
Net-Shape CoreNet-Shape Core
CuttingCutting HandlingHandling HP-RTMHP-RTMCuttingCutting HandlingHandling HP RTMHP RTM
UD Braided Cross BeamUD Braided Cross Beam
Process Chain
SMC End-CapsSMC End-Caps StackingStacking HandlingHandling Auto-RTMAuto-RTM
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
Process Chain
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Manufacturing ConceptJune 2013FRP E-Mobile Battery Case - Concept Study
64 i l li64 single plies
application of multiaxialMaterial:
32 plies
32 cutting steps
3 stacking steps
5 preforms for preforming
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
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ManufacturingJune 2013FRP E-Mobile Battery Case - Concept Study
90° + 45°
0°
- 45°
sandwich panel
foam core handling device NCF handling device
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
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g g
ManufacturingJune 2013FRP E-Mobile Battery Case - Concept Study
UD Braiding 0° ply application+/-° ply application
Cross Beam
Industrial Scenario
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
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Manufacturing Feasibility DemonstratorJune 2013FRP E-Mobile Battery Case - Concept Study
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
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June 2013FRP E-Mobile Battery Case - Concept Study
© CTC GMBH. Alle Rechte vorbehalten. Vertrauliches und geschütztes Dokument.Dieses Dokument und alle darin enthaltenen Informationen sind das alleinige Eigentum derCTC GMBH. Die Zustellung dieses Dokumentes oder die Offenlegung seines Inhaltsbegründen keine Rechte am geistigen Eigentum. Dieses Dokument darf ohne dieausdrückliche schriftliche Genehmigung der CTC GMBH nicht vervielfältigt oder einemausdrückliche schriftliche Genehmigung der CTC GMBH nicht vervielfältigt oder einemDritten gegenüber enthüllt werden. Dieses Dokument und sein Inhalt dürfen nur zubestimmungsgemäßen Zwecken verwendet werden.Die in diesem Dokument gemachten Aussagen stellen kein Angebot dar. Sie wurden auf derGrundlage der aufgeführten Annahmen und in gutem Glauben gemacht. Wenn diezugehörigen Begründungen für diese Aussagen nicht angegeben sind, ist die CTC GMBHgern bereit, deren Grundlage zu erläutern.
© CTC GMBH. All rights reserved. Confidential and proprietary document.CTC GmbH is a100% subsidiary of AIRBUS Operations GmbH
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. This document and all information contained herein is the sole property of AIRBUS S.A.S. No intellectual property rights are granted by thedelivery of this document or the disclosure of its content. This document shall not be reproduced or disclosed to a third party without the express written consent of AIRBUS S.A.S. This document and its content shall not beused for any purpose other than that for which it is supplied. The statements made herein do not constitute an offer. They are based on the mentioned assumptions and are expressed in good faith. Where the supportinggrounds for these statements are not shown, AIRBUS S.A.S. will be pleased to explain the basis thereof.AIRBUS, its logo, A300, A310, A318, A319, A320, A321, A330, A340, A350, A380, A400M are registered trademarks.
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