Purdue EcoCAR 2 Presentation at PACE Annual Forum

Purdue University EcoCAR 2

Packaging and Structural Analysis of Component Integration Using Siemens NX for the Purdue EcoCAR2 Plug-in Hybrid-Electric Vehicle

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Presentation Overview

2 2

Introduction

• Competition Details

• Vehicle architecture

• Mechanical subsystems

Battery Box

• Packaging battery modules

• Routing electrical cables

• Fabrication

Rear Suspension Cradle

• Subsystem Design

• Finite Element stress Analysis

• Fabrication

Rear Suspension Upper Camber link

• Design

• FEA

• Fabrication

Competition Details

3 3

Vehicle Architecture

4

Fron

t

2.4 L Gasoline Engine

6-speed Auto Transmission

Fuel Tank

Final Drive


Electrical Fuel Mechanical


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Fron

t

1.7L B20 CI Engine

6-speed Auto Transmission

Fuel Tank

ESS (A123

6s15p3)

Brusa Battery Charger Magna

Motor + Inverter

Final Drive


Electrical Fuel Mechanical


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Fuel Tank

Diesel Engine

Transmission

Suspension

Cradle

Rear Traction Motor

Battery Box

Mechanical Subsystems

7 7

Energy Storage System (ESS) Rear Suspension Cradle Rear Suspension Camber Link

Battery Box Design

8 8

Packaging Constraints

Battery Box Design

9 9

Module Placement

Battery Box Design

10 10

Module Placement

Battery Box Design

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Module Placement

Battery Box Design

12 12

Module Placement

Battery Box Design

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Module Placement

Battery Box Design

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Module Placement

Assembly: Construction of the Battery Box

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Battery Box Design

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Electrical Routing

Battery Box Design

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Fabrication


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L1

L2


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Design


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Finite Element Analysis


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Fabrication


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Fabrication

Upper Camber Link

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Design

Upper Camber Link

55 55

Design

Upper Camber Link

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Design

Upper Camber Link

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Design

Rear Suspension

58 58


•Tested 7 load cases provided by GM

•Max load of 21081N

•Max Torque of 48504N-mm

•Meshed with tetrahedral elements

•2.41 to 2.59 times factor of safety compared to stock part

•1.01 to 1.12 times as stiff as stock

Rear Suspension

59 59

Fabrication

Vehicle Assembly

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Vehicle Assembly

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• Battery Box

Vehicle Assembly

62 62

• Battery Box

• Rear Traction Motor

Vehicle Assembly

63 63

• Battery Box


• Rear Suspension Cradle

Vehicle Assembly

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• Battery Box


• Rear Suspension Cradle

• Upper Camber Link

Questions

65

Thank you for your attention!

•Questions?

Purdue EcoCAR 2 Presentation at PACE Annual Forum

Technology

Transcript of Purdue EcoCAR 2 Presentation at PACE Annual Forum