Electric Vehicle Body Research Articles

The toughness of polymer reinforced pineapple-leaf fibers for the electric car body application

Abstract Pineapple-leaf fiber (PALF) belongs to the plant-based fiber group that has been highly abundant recently. However, PALF was no longer used and thrown away as agricultural waste. In fact, PALF can be used as alternative reinforcement for composite materials due to its properties. Composite materials have been used in the aircraft, automotive and household furniture industries. The objective of this research was to investigate the impact properties of epoxy resin matrix reinforced with glass fiber and PALF. The ASTM D256-23 standard was carried out when performing the impact test. The result showed that the composite material consists of PALF had higher impact strength compared to the composite reinforced by glass fiber. The compatibilities of fiber and matrix became main factor that affect significantly the value. This was confirmed by the porosities test results. Therefore, PALF was proven its reliability to substitute the synthetic one such as glass fiber to strengthening the composite materials for electric vehicle body application.

Electromagnetic field simulation modeling method and distribution characteristics of electric vehicle wireless charging system

In recent years, wireless charging technology for electric vehicles has gained significant attention. To accurately analyze the distribution characteristics of the electromagnetic field during the wireless charging process of electric vehicles, a finite element-based electromagnetic analysis method was employed. Applied in the commercial simulation software, the electromagnetic environment of the resonant coil and electric vehicle model was simulated under high-power charging conditions, resulting in an overall electromagnetic field distribution for the electric vehicle. The results indicated that within the coil region, the magnetic induction intensity in the central area of the coil was zero, and it increased as the distance from the center of the coil grew. Outside the coil region, the magnetic induction intensity gradually decreased. The electric field intensity of the resonant coil was maximum in the central area of the coil, and it weakened as the distance from the center of the coil increased. When a magnetic shielding resonant coil was used, the electromagnetic field was confined between the shielding materials, and the magnetic field rapidly attenuated on both sides of the magnetic shield. The electromagnetic field energy of the electric vehicle body was mainly concentrated at the bottom of the vehicle near the coil. When the coil was located in the front of the car body, the maximum electric field intensity distribution in the car body was 8.50 V/m, and the maximum magnetic induction intensity was 0.024 μT. When the coil was located in the middle of the car body, the maximum electric field intensity was 2.31 V/m, the maximum magnetic induction intensity was 0.019 μT. As the distance from the coil position increased, the energy weakened.

Analysis of longitudinal-vertical coupling vibration of four hub motors driven electric vehicle under unsteady condition

The influence of hub motor unbalanced magnetic force (UMF) on the vibration of electric vehicle under steady state conditions has been known, but under unsteady conditions, the hub motor UMF will change with the vehicle operation condition, and there would exist complex coupling vibration for the hub motors driven electric vehicle. Here, the longitudinal-vertical coupling dynamics of the four hub motors driven electric vehicle under unsteady condition is studied. Integrating the motor electromagnetic excitation and electric vehicle dynamics, a longitudinal-vertical coupling dynamics model of the four hub motors driven electric vehicle is established. Based on the variable switching frequency field-oriented control model, analytical model of the UMFs acting on the motor stator and rotor parts under unsteady condition are developed. For model validation, a four hub motors driven electric vehicle has been tested, the accuracy of the longitudinal-vertical coupling dynamics model established in this paper was verified. Then, longitudinal-vertical coupling vibration characteristics of the four hub motors driven electric vehicle under road excitation and coupling excitation are analyzed. The results show that the longitudinal and vertical movement of the four hub motors driven electric vehicle is coupled by hub motor. In addition, under unsteady condition, the motor UMFs will cause vertical vibration of the electric vehicle body and hub motor stator, the vibration shows order characteristics including low order harmonic hfc and inverter switching frequency sideband harmonic k1 fs±k2 fc ( fc = pn/60, fs is inverter switching frequency, k1 and k2 are positive integers, p is the number of pole pairs and n is motor speed.). The motor electromagnetic torque will cause longitudinal vibration of the electric vehicle body, the vibration shows order characteristics including harmonics fs±3 fc and 2 fs. The main harmonic of vehicle body pitch angle acceleration is 2 fs.

Multi-Objective Prediction of the Sound Insulation Performance of a Vehicle Body System Using Multiple Kernel Learning–Support Vector Regression

The sound insulation performance of an electric vehicle’s body system serves as a critical metric for evaluating the noise, vibration, and harshness (NVH) quality of the vehicle. The accurate and efficient prediction of sound insulation performance is foundational for undertaking noise reduction design and optimization. Current engineering practices predominantly rely on Computer-Aided Engineering (CAE) methodologies to address this challenge. However, inherent shortcomings such as low modeling efficiency and difficulty in ensuring prediction accuracy often characterize these approaches. In an effort to overcome these limitations, we propose a decomposition framework for predicting the sound insulation performance of the electric vehicle body system. This framework is established based on a comprehensive analysis of the noise transmission paths within the system. Subsequently, the support vector regression (SVR) method is introduced to construct a machine learning model specifically designed for predicting the sound insulation performance of the body system. This approach aims to mitigate the inherent weaknesses associated with the conventional CAE processes using a ‘data-driven’ paradigm. Furthermore, the Multiple Kernel Learning (MKL) method is used to enhance the processing efficacy of the SVR model. The proposed method is validated using practical application and testing on a specific electric vehicle. The results demonstrate commendable performance in terms of prediction accuracy and robustness. This research contributes to advancing the field by presenting a more effective and reliable approach to predicting the sound insulation performance of electric vehicle body systems, offering valuable insights for noise reduction strategies and optimization efforts in the automotive industry.

EVALUATION OF ELECTROMAGNETIC FIELDS IN HUMAN BODY EXPOSED TO INVERTER OF PURE ELECTRIC VEHICLE.

On the basis of the basic principle of electromagnetic dosimetry, the paper studies the electromagnetic exposure of a passenger's body to a compound electromagnetic field caused by the combined action of DC and AC bus currents of a pure electric vehicle inverter. By building an electromagnetic model of a pure electric vehicle body, adult human body and inverter, the finite element method is used to calculate the magnetic induction intensity(|B|), induced electric field intensity(|E|) and induced current density(|J|) of the compound electromagnetic field to the human trunk and central nervous system in the driver and front seat passenger. The numerical results are compared with the exposure limits defined by the International Commission on Non-Ionizing Radiation Protection (ICNIRP). The fields are well below the safe exposure limits defined by ICNIRP.

Design Optimization of Energy‐Storing Hybrid Supercapacitor Composite for Electric Vehicle's Body Panel

As electric vehicles (EVs) are evolving, innovative technologies like “energized composite” that can store energy in the car's body helps extend its range per charge. The composite's unique ability to function as both structural body panel and charge storage medium stems from its unique pattern design between “electrochemical areas (EcA)” and “epoxy area (EpA)”. Herein, a design optimization study is presented to obtain a balanced ratio between EcA versus EpA to maximize the charge storage ability of the composite while maintaining a decent tensile and bending strength. Simulations using ANSYS software and experimental confirmation using universal testing machines and electrochemical analyzers are used to derive optimum ratios between EcA and EpA. Uniaxial tension test and 3‐point bend test have been performed to optimize the tensile and bend strengths, whereas cyclic voltammetry, galvanic charge–discharge, and electrochemical impedance spectroscopy are used to determine the electrochemical performance of various design configurations by modulating the ratios of EcA versus EpA. Overall, the highest achieved energy storage per lamina is 2531 mWh m−2 for a maximum of 81.6% EcA with a tensile strength of 417.73 MPa and bending strength of 263.13 MPa. This study is highly beneficial for EVs and aerospace applications.

Electric vehicles body frame structure design method: An approach to design electric vehicle body structure based on battery arrangement

Although the electric vehicles (EVs) have become the main development of the automotive industry, there is still very limited knowledge about the design method of EVs’ body structure. This paper substantially increases this limited knowledge by developing an EV’s aluminum alloy body frame structure design (EVFD) method based on battery arrangements. The main concept of the EVFD approach is the development of the parametric knowledge base to facilitate performance driven design of body structure in concept design stage, including the battery sub-libraries designed by vehicle power performances and the modular body frame structure sub-libraries and cross section of profile sub-libraries designed by structure performances. The layout of vehicle is firstly determined based on battery volume which calculated on the basis of power performance of EVs. And then, the body frame structures are designed by multi-load topology optimization and multi-objective parametric optimization based on the body structure performance, considering the battery layout and its mass distribution. The developed body structure knowledge base is screened through comparing their structural mechanical properties. The feasibility and accuracy of selected EV’s aluminum alloy body frame structure is verified by experiment. In this paper, the case study demonstrates that the proposed EVFD method based on battery arrangement can be effectively used to design aluminum alloy body frame structure of EVs, which provides a reference to other EV’s body structure design. Due to the performance driven design concept employed, the designed body structure for EV meets the requirements of lightweight, dynamic performance, and structural mechanical properties.

Influence of different materials of electric vehicle body on low frequency electromagnetic exposure for driver

For electric vehicles(EVs), in addition to the power system is its core technology, the use of the new body materials with stronger hardness, lighter weight and better shielding performance is also one of the important issues concerned by the EVs industry. The distribution of induction field in the trunk and the central nervous system (CNS) of the driver’s is studied with the vehicle body materials are aluminum alloy, non-magnetic steel, metal X and permalloy. The results show that the maximum values of induced electric field intensity(E-field) and induced current density(J-field) in the driver’s trunk only reach 2.27% and 67% of the International Commission on Non-Ionizing Radiation Protection(ICNIRP) limits respectively, and the maximum values of E-field and J-field in the driver’s CNS only reach 0.29% and 0.62% of the ICNIRP limits respectively. So, the electromagnetic exposure levels of the driver’s body are within the safe range in this situation. In short, the EVs body material with the higher resistivity and relative permeability would make the electromagnetic exposure level for the driver’s body in a much lower level, and it is also much safer for the driver’s body from the perspective of electromagnetic dosimetry.

Experimental Approach and CFD Simulation of Battery Electric Vehicle Body

Aerodynamic is considered the most significant factor affecting on vehicles fuel consumption and power requirements even at low speed. For this reason, there are much interest and some modifications that decrease drag coefficient and reduce the aerodynamic effectiveness. This study aims to develop an electrical car body (ECB) to decrease the drag coefficient and study the reflection of this parameter in the power consumption rate in different operating speeds. Six different models for car bodies (Bendra, Magenta, Violet, Bluria, Aqua and Vectra) with same wheelbase, height, and track width dimensions are designed. The design of these models has done using Solidworks software by surface tools. Numerical results (frontal area, drag coefficient, drag area and drag force) for the six models are recorded and compared to choose the best designed body. According to results Vectra model is chosen as a best design. The power consumption is calculated for each model at different operating speeds using two different software, Solidworks flow simulation and ANSYS fluent. Experimental results are obtained by testing 3D printing model for the best efficient model with scale 1: 25 at small subsonic open wind tunnel. The experimental results show good agreement with simulation results. Finally, Vectra simulation and experimental results are compared with the real electric and petrol cars to verify the competitive design for Vectra model.

Innovative Electric Vehicle Body Design Based on Insurance Institute for Highway Safety Side Impact Conditions

A version of an electric vehicle was developed and designed for the US market on the basis of the required domestic body structure. When compared with the original car, the new car body design leads to two major technical difficulties. First, the installation of high-voltage components such as the battery pack and other new energy sources increases the vehicle weight and occupies a great deal of its structural space; this limits the impact paths and the use of traditional structural designs, which greatly increases the design difficulty. Second, the USA, as an advanced automobile-using country, has well-developed laws and regulations for collision standards, vehicle operating conditions and evaluation standards. Using a combination of butterfly diagram analysis, bending moment management, section forces and other computer-aided simulation and analysis techniques, this paper presents a body structure design that can achieve a “GOOD” evaluation under the US Insurance Institute for Highway Safety (IIHS) side impact body structure conditions by optimizing the force transfer path, the B-pillar deformation mode and the threshold support structure. The threshold support structure supports realization of the “GOOD” rating for IIHS side impact and helps the body to meet the crash requirements of the Federal Motor Vehicle Safety Standard FMVSS214 and the US New Car Assessment Program (NCAP) requirements for side impact at 32 km/h and 75° angular pole impact.

The Bending Responses of Sandwich Panels with Aluminium Honeycomb Core and CFRP Skins Used in Electric Vehicle Body

The aim of this paper was to investigate bending responses of sandwich panels with aluminium honeycomb core and carbon fibre‐reinforced plastic (CFRP) skins used in electric vehicle body subjected to quasistatic bending. The typical load‐displacement curves, failure modes, and energy absorption are studied. The effects of fibre direction, stacking sequence, layer thickness, and loading velocity on the crashworthiness characteristics are discussed. The finite element analysis (FEA) results are compared with experimental measurements. It is observed that there are good agreements between the FEA and experimental results. Numerical simulations and experiment predict that the honeycomb sandwich panels with ±30° and ±45° fibre direction, asymmetrical stacking sequence (45°/−45°/45°/−45°), thicker panels (0.2 mm∼0.4 mm), and smaller loading velocity (5 mm/min∼30 mm/min) have better crashworthiness performance. The FEA prediction is also helpful in understanding the initiation and propagation of cracks within the honeycomb sandwich panels.

Research on Air Suspension Control System Based on Fuzzy Control

In order to solve the suspension overshoot phenomenon existing in the static regulation process of the electric vehicle with electric controlled air suspension, firstly, the relevant factors of air spring are analyzed and the characteristics of the gasbag are simulated and verified in AMESim. Secondly, the model of the electric vehicle body is analyzed according to the law of dynamics and the fuzzy control theory is used to set up the electric vehicle body model in Simulink. In the case of unbalanced load, the effectiveness of the fuzzy controller is used to simulate the phenomenon of “overshoot” in the system.

Design of Body Structure for New Type Lightweight Electric Vehicle

Considering the efficient use of energy and environmental pollution, people's lives tend to energy saving and environmental protection, and energy saving electric vehicles has gradually been widely used. Through combining theoretical analysis, numerical simulation, system design and experimental validation, based on studying electric vehicle body design principles, the experiment optimized electric vehicle body design, and reduced the weight of the vehicle effectively. Its performance becomes more advanced, and the application becomes more economical and safe. By using Solidworks software, lightweight electric vehicle body structure of two-dimensional design and three-dimensional modeling was built to reach practical requirements. The body structure design is original and simple, which has good practical value.

Lightweight design of carbon twill weave fabric composite body structure for electric vehicle

Design of composite appears more challenging compared with metallic counterparts because of its microstructural heterogeneity and behavioral sophistication. This paper aims to develop a multiscale approach for predicting three-dimensional elastic model of carbon twill weave fabric composite which will be applied to crashworthiness analysis of body structure of electric vehicle. The geometric parameters were obtained by measuring the microstructure of T300 carbon twill weave fabric composite through optical microscopy. The finite element model of representative volume element (RVE) in laminate composite was established to characterize the elastic properties of the materials using the homogenization technique. The numerical results of property were compared with those from uniaxial tensile and three point bending tests. Finally, the constitutive model of such composite was employed to crashworthiness analysis for electric vehicle body structure under the roof crash and side pole impact. The study indicates that the deformation behaviors of laminate calculated by using the elastic properties are in good agreement with tensile and bending experimental results with maximum relative errors of 4.04% and 7.79%, respectively. Meanwhile, a 28% savings of body weight is achieved using the carbon twill weave fabric composite compared to its predecessor made of glass fiber reinforced plastics (GFRP).

Topology Optimization of a Parallel Hybrid Electric Vehicle Body in White

Topology optimization design of a parallel hybrid electric vehicle (HEV) body in white (BIW) by applying Solid Isotropic Microstructure with Penalization (SIMP) method is presented. The BIW optimization of HEV takes into account not only the static loads, but also the loads of HEV in turning and braking conditions. Torsion playing a leading role in vehicle turning process and bending playing a leading role in vehicle braking process are converted to related vertical force imposed on the optimal model. The optimal result shows clear skeleton body in white of parallel HEV when volumetric constraint is 25%. Beam appears in the top of optimal automotive body in white when volumetric constraint is 40%. There is no significant change except increased thickness for the basis body in white of parallel HEV when volumetric constraints continue to enlarge.

Topology Optimization of Electric Vehicle Body in White Based on SIMP Method

Based on Solid Isotropic Microstructure with Penalization (SIMP) method, a mathematical model for topology optimization of EV is proposed, which has design objective as minimizing compliance, with volumetric and geometric constraints. To make results more engineering value, the BIW optimization of EV takes into account not only the static loads, but also the torsion load in turning and moment load in braking process of EV. A number of implementation aspects in solving the numerical instability problem generated in optimization process are discussed, including checkboard patterns and mesh-dependency. Topology optimization of EV body in white with geometry and volumetric constraints is conducted, showing effectiveness of the proposed model.