A New Body Concept for Electric Vehicle: PBC-EV

Abstract

POSCO developed a new body concept for electric vehicle, POSCO Body Concept—Electric Vehicle (PBC-EV) with the aim to provide steel solutions to the challenges facing automakers around the world to increase the fuel efficiency of automobiles and reduce greenhouse gas emissions, while improving safety, performance and maintaining affordability. The objectives are achieved by advanced steel grades, engineering design optimization and advanced steel technologies with the best attributes of steel—its design flexibility, strength, formability, low manufacturing emissions and comparative low cost. PBC-EV features steel body structure designs that reduce weight to 218 kg by 26 % over a benchmarking body of 296 kg. The weight reduction has been realized through the use of advanced high strength steel grades by 64 % of total body weight combined with the aforementioned steel technologies. Even though there is a cost premium associated with the use of higher grade steels, the consequently achieved weight savings minimize the increase of overall costs of manufacturing and assembly. A total life cycle emission of PBC-EV is reduced by nearly 50 % comparing to benchmarking internal combustion engine vehicle. These are accomplished while meeting a broad list of global safety requirements such as US FMVSS, IIHS and EuroNCAP. No damage of battery cell in the crash simulations is observed. In the last stage hardware demonstration was done by building Body-in-White (BIWs) excluding opening parts and fenders. With this study advanced steel solutions which are not only lighter and safer but greener can be provided to automakers. And it is very important for automakers to avoid unintended consequences by using eco-friendly steel technologies for advanced powertrain vehicle.