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Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
Purdue EcoCAR 2 Presentation at PACE Annual Forum
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Purdue EcoCAR 2 Presentation at PACE Annual Forum

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Adam Fogarty and Kevin Oswald presented at the PACE Annual Forum in July 2013. They provided insights on using NX software from Siemens for packaging and structural analysis of component integration …

Adam Fogarty and Kevin Oswald presented at the PACE Annual Forum in July 2013. They provided insights on using NX software from Siemens for packaging and structural analysis of component integration on a plug-in electric vehicle.

Published in: Technology, Business
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Transcript

  • 1. Purdue University EcoCAR 2 Packaging and Structural Analysis of Component Integration Using Siemens NX for the Purdue EcoCAR2 Plug-in Hybrid-Electric Vehicle 1
  • 2. Presentation Overview 22 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
  • 3. Competition Details 33
  • 4. Vehicle Architecture 4 Front 2.4 L Gasoline Engine 6-speed Auto Transmission Fuel Tank Final Drive Vehicle Architecture Electrical Fuel Mechanical
  • 5. Vehicle Architecture 5 Front 1.7L B20 CI Engine 6-speed Auto Transmission Fuel Tank ESS (A123 6s15p3) Brusa Battery ChargerMagna Motor + Inverter Final Drive Vehicle Architecture Electrical Fuel Mechanical
  • 6. Vehicle Architecture 6 Vehicle Architecture Fuel Tank Diesel Engine Transmission Suspension Cradle Rear Traction Motor Battery Box
  • 7. Mechanical Subsystems 77 Energy Storage System (ESS) Rear Suspension Cradle Rear Suspension Camber Link
  • 8. Battery Box Design 88 Packaging Constraints
  • 9. Battery Box Design 99 Module Placement
  • 10. Battery Box Design 1010 Module Placement
  • 11. Battery Box Design 1111 Module Placement
  • 12. Battery Box Design 1212 Module Placement
  • 13. Battery Box Design 1313 Module Placement
  • 14. Battery Box Design 1414 Module Placement
  • 15. Assembly: Construction of the Battery Box 15
  • 16. Assembly: Construction of the Battery Box 16
  • 17. 17 Assembly: Construction of the Battery Box
  • 18. 18 Assembly: Construction of the Battery Box
  • 19. 19 Assembly: Construction of the Battery Box
  • 20. 20 Assembly: Construction of the Battery Box
  • 21. 21 Assembly: Construction of the Battery Box
  • 22. 22 Assembly: Construction of the Battery Box
  • 23. 23 Assembly: Construction of the Battery Box
  • 24. 24 Assembly: Construction of the Battery Box
  • 25. 25 Assembly: Construction of the Battery Box
  • 26. 26 Assembly: Construction of the Battery Box
  • 27. 27 Assembly: Construction of the Battery Box
  • 28. 28 Assembly: Construction of the Battery Box
  • 29. 29 Assembly: Construction of the Battery Box
  • 30. 30 Assembly: Construction of the Battery Box
  • 31. 31 Assembly: Construction of the Battery Box
  • 32. 32 Assembly: Construction of the Battery Box
  • 33. 33 Assembly: Construction of the Battery Box
  • 34. 34 Assembly: Construction of the Battery Box
  • 35. 35 Assembly: Construction of the Battery Box
  • 36. 36 Assembly: Construction of the Battery Box
  • 37. 37 Assembly: Construction of the Battery Box
  • 38. 38 Assembly: Construction of the Battery Box
  • 39. Battery Box Design 3939 Electrical Routing
  • 40. Battery Box Design 40 Fabrication
  • 41. Rear Suspension Cradle 4141
  • 42. Rear Suspension Cradle 4242 L1 L2
  • 43. Rear Suspension Cradle 4343
  • 44. Rear Suspension Cradle 4444
  • 45. Rear Suspension Cradle 4545 Design
  • 46. Rear Suspension Cradle 4646 Finite Element Analysis
  • 47. Rear Suspension Cradle 4747 Finite Element Analysis
  • 48. Rear Suspension Cradle 4848 Finite Element Analysis
  • 49. Rear Suspension Cradle 4949 Finite Element Analysis
  • 50. Rear Suspension Cradle 5050
  • 51. Rear Suspension Cradle 5151 Finite Element Analysis
  • 52. Rear Suspension Cradle 5252 Fabrication
  • 53. Rear Suspension Cradle 5353 Fabrication
  • 54. Upper Camber Link 5454 Design
  • 55. Upper Camber Link 5555 Design
  • 56. Upper Camber Link 5656 Design
  • 57. Upper Camber Link 5757 Design
  • 58. Rear Suspension 5858 Finite Element Analysis •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
  • 59. Rear Suspension 5959 Fabrication
  • 60. Vehicle Assembly 6060
  • 61. Vehicle Assembly 6161 • Battery Box
  • 62. Vehicle Assembly 6262 • Battery Box • Rear Traction Motor
  • 63. Vehicle Assembly 6363 • Battery Box • Rear Traction Motor • Rear Suspension Cradle
  • 64. Vehicle Assembly 6464 • Battery Box • Rear Traction Motor • Rear Suspension Cradle • Upper Camber Link
  • 65. Questions 65 Thank you for your attention! •Questions?

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