Design and optimization of electric bus monocoque structure consisting of composite materials

Abstract

This paper proposes a novel design methodology for electric-bus structures by implementing the finite element method via ABAQUS™ and linear programming via MATLAB™. A monocoque sandwich-structured fiber-reinforced composite bus with a maximum driving range of 300 km is conceived using the proposed methodology. The bus-body structure is designed based on safety criteria such as vehicle registration regulations, the strength of the bus structure under various driving conditions, bending- and torsion-stiffness requirements, and the rollover testing standard of UN ECE R66. A procedure developed to systematically conduct parametric studies by varying the core and face thicknesses of the sandwich structure of each component is presented. Multivariate functions are formulated to determine the correlations of structural responses with changes in geometric parameters. Linear programming is implemented to minimize the mass of the bus structure under design constraints. The proposed monocoque bus structure meets all requirements, and its body mass is 63.3% less than the benchmark value.