Virtual crash safety optimisation...

The electric vehicle which is fun and affordable: Life, an innovative urban car from e.GO Mobile AG.

e.GO Mobile AG commissioned TECOSIM to develop a crash-optimised vehicle body.

The Challenge

The focus during development for e.GO Life was on the accident-proof design of safety-relevant high-voltage components, as well as occupant safety.

Potential danger to occupants and any damage to the rechargeable batteries had to be eliminated.

During crash safety optimisation, TECOSIM’s Computer-Aided Engineering specialists also geared development towards reducing vehicle weight, project time and costs.

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Project Description Info Box

  • Development of the crash-optimised body model
  • Simulation of different frontal (ECE-R94, ECE-R137) and side impacts (barrier, post)
  • Calculation and simulation of the Allianz Centre of Technology insured event
  • Finite element (FE) calculations to select material quality grades and thickness widths

e.GO

Situated at RWTH Aachen University’s campus, e.GO Mobile AG develops and builds electric vehicle concepts.

Rapid advances in development have been achieved thanks to innovative approaches to creating a new electric car and providing production Industry 4.0 optimisation.

The final design of the e.GO Life will go into series production in an Industry 4.0 plant as of 2018.

For further information on e.GO: www.e-go-mobile.com

Results

  • Calculation and protection of the vehicle body platform
  • Successful front impact in the small overlap test
  • Calculations for rear impact load and car body optimisation
  • Weight optimisation with the aid of finite element (FE) calculations

TECOSIM Company Profile

A team of over 460 computer-aided engineering (CAE) specialists positions TECOSIM as the go-to development process partner.

With branches in the UK, Japan, India, Germany and Romania we deliver unbeatable solutions that fully satisfy your requirements.

TECOSIM Company Profile

A team of over 460 computer-aided engineering (CAE) specialists positions TECOSIM as the go-to development process partner. With branches in the UK, Japan, India, Germany and Romania we deliver unbeatable solutions that fully satisfy your requirements.

The Solution

TECOSIM simulated a variety of frontal impacts, working closely with the e.GO team. The aim was to develop a crash-optimised vehicle body based on the CAD design.

The TECOSIM engineers utilized finite element (FE) calculations to produce recommendations to select material grades and thickness widths. Crash performance was greatly enhanced, and weight was reduced.

The new electric car was created in just a third of the usual development time and at 10% of the cost.

  • Development of a laminated glass simulation method which far exceeds previous standards
  • High prediction accuracy regarding the risks of injury for head impacts on a windscreen
  • Simulation results can be incorporated into new car designs immediately
  • Recommendations for improvements to structural designs for windscreens and panoramic windscreens.
  • A research project funded by the German Federal Ministry of Economics and Technology (BMWi).

TECOSIM Services

Front and side impact crash simulations

TECOSIM’s tested load cases as per statutory regulations ECE-R94 and ECE-R137 (frontal impacts against rigid and flexible walls).

These scenarios are challenging for electric vehicles. Accident-proof housing for high-voltage components takes priority – this is the only way to eliminate any danger to occupants without causing damage to the battery package.

Vehicle body crash optimisation

The e.GO Life is based on a frame concept with composite panelling. The structure is mostly aluminium with the exception of the A column and exterior roof frame.

During crash optimisation, TECOSIM had to guarantee structural rigidity. Vehicle weight and cost needed to be kept within strict limits.

To achieve this, computer-aided engineering (CAE) specialists calculated geometric modifications whilst introducing local reinforcements to enhance crash behavior.

An exceptionally sturdy structure was developed resulting in greater crash safety.

Weight reduction calculations 

Reduction of an electric vehicle’s weight is key. e.GO’s design concept stipulated that the number of materials, sheet thickness widths and configurations needed to be kept to a bare minimum.

By using FE calculations, TECOSIM proposed solutions to select material grades and thickness widths.

Benefit to the client

The result of this challenging task was the production of a comparatively lightweight vehicle body. Budget requirements were met whilst the solution complied with all mandatory safety requirements.