Purdue University EcoCAR 2
Packaging and Structural Analysis of Component
Integration Using Siemens NX for the Purdue
EcoC...
Presentation Overview
22
Introduction
• Competition Details
• Vehicle architecture
• Mechanical subsystems
Battery Box
• P...
Competition Details
33
Vehicle Architecture
4
Front
2.4 L
Gasoline
Engine
6-speed Auto
Transmission
Fuel Tank
Final Drive
Vehicle Architecture
El...
Vehicle Architecture
5
Front
1.7L B20
CI Engine
6-speed Auto
Transmission
Fuel Tank
ESS
(A123
6s15p3)
Brusa
Battery
Charge...
Vehicle Architecture
6
Vehicle Architecture
Fuel Tank
Diesel Engine
Transmission
Suspension
Cradle
Rear Traction Motor
Bat...
Mechanical Subsystems
77
Energy Storage System (ESS) Rear Suspension Cradle Rear Suspension Camber Link
Battery Box Design
88
Packaging Constraints
Battery Box Design
99
Module Placement
Battery Box Design
1010
Module Placement
Battery Box Design
1111
Module Placement
Battery Box Design
1212
Module Placement
Battery Box Design
1313
Module Placement
Battery Box Design
1414
Module Placement
Assembly: Construction of the Battery Box
15
Assembly: Construction of the Battery Box
16
17
Assembly: Construction of the Battery Box
18
Assembly: Construction of the Battery Box
19
Assembly: Construction of the Battery Box
20
Assembly: Construction of the Battery Box
21
Assembly: Construction of the Battery Box
22
Assembly: Construction of the Battery Box
23
Assembly: Construction of the Battery Box
24
Assembly: Construction of the Battery Box
25
Assembly: Construction of the Battery Box
26
Assembly: Construction of the Battery Box
27
Assembly: Construction of the Battery Box
28
Assembly: Construction of the Battery Box
29
Assembly: Construction of the Battery Box
30
Assembly: Construction of the Battery Box
31
Assembly: Construction of the Battery Box
32
Assembly: Construction of the Battery Box
33
Assembly: Construction of the Battery Box
34
Assembly: Construction of the Battery Box
35
Assembly: Construction of the Battery Box
36
Assembly: Construction of the Battery Box
37
Assembly: Construction of the Battery Box
38
Assembly: Construction of the Battery Box
Battery Box Design
3939
Electrical Routing
Battery Box Design
40
Fabrication
Rear Suspension Cradle
4141
Rear Suspension Cradle
4242
L1
L2
Rear Suspension Cradle
4343
Rear Suspension Cradle
4444
Rear Suspension Cradle
4545
Design
Rear Suspension Cradle
4646
Finite Element Analysis
Rear Suspension Cradle
4747
Finite Element Analysis
Rear Suspension Cradle
4848
Finite Element Analysis
Rear Suspension Cradle
4949
Finite Element Analysis
Rear Suspension Cradle
5050
Rear Suspension Cradle
5151
Finite Element Analysis
Rear Suspension Cradle
5252
Fabrication
Rear Suspension Cradle
5353
Fabrication
Upper Camber Link
5454
Design
Upper Camber Link
5555
Design
Upper Camber Link
5656
Design
Upper Camber Link
5757
Design
Rear Suspension
5858
Finite Element Analysis
•Tested 7 load cases provided by GM
•Max load of 21081N
•Max Torque of 48504N...
Rear Suspension
5959
Fabrication
Vehicle Assembly
6060
Vehicle Assembly
6161
• Battery Box
Vehicle Assembly
6262
• Battery Box
• Rear Traction Motor
Vehicle Assembly
6363
• Battery Box
• Rear Traction Motor
• Rear Suspension Cradle
Vehicle Assembly
6464
• Battery Box
• Rear Traction Motor
• Rear Suspension Cradle
• Upper Camber Link
Questions
65
Thank you for your attention!
•Questions?
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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 on a plug-in electric vehicle.

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Purdue EcoCAR 2 Presentation at PACE Annual Forum

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

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