Abstract

The focus in this paper is on the latest results of the crash, reuse and remanufacturing design concepts for a durable sill structure for a modular vehicle platform architecture. Like the entire vehicle platform the sill structure is also designed modular, with the possibility to replace damaged or to reuse intact components. The innovative sill structure consists mainly of durable carbon fiber reinforced composite plastic (CFRP) crash absorbers in the form of tubes and a C-profile manufactured by a cost effective serial process – pultrusion. Those crash tubes were designed using experimental and numerical knowledge based on internal studies. A special layup was chosen to achieve the highest energy absorption in case of a crash. Therefore, the mechanism of crushing and inversion are targeted. The innovative alignment of the crash tubes consider protection against oblique impact according to the latest NCAP standards. For a smooth transmission of the incoming force into the tubes, an auxetic-structured buffer element is placed between the outer C-profile and the crash tubes. In case of a crash or a vehicle design change, intact crash tubes can be reused or remanufactured thanks to the high durability and detachable connections, which corresponds to a cycle concept.

Highlights

  • The automotive production as a very energy and resource consuming economy is an important point to rethink the state of the art structures with the aim of generating a more eco-friendly future for example by means of circular economy

  • The focus in this paper is on the latest results of the crash, reuse and remanufacturing design concepts for a durable sill structure for a modular vehicle platform architecture

  • A development path for a long-lasting sill structure with the focus on the impact protection elements and a reuse friendly design was shown from the basic idea till manufacturing

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Summary

Introduction

The automotive production as a very energy and resource consuming economy is an important point to rethink the state of the art structures with the aim of generating a more eco-friendly future for example by means of circular economy. One step ahead in this direction could be a vehicle platform, which is long-lasting in the use. This is the basic idea of the project “KOSEL” [1]. The project is funded within the funding measure “Resource-efficient Circular Economy – Innovative Product Cycles (ReziProK)“. The entire platform is designed with the focus on component durability and interchangeability. This is intended to reduce maintenance costs and achieve a longer life for the vehicle, especially the platform. The service life of the platform is decisive for the overall service life of the vehicle. This work is mainly focused on the development of the side crash protection for this novel platform and a reuse friendly design

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