Systems Focused Product Development Of The Hypercar

Systems Focused Product Development of the Hypercar April 29, 2002

Hypercar, Inc.

what is Hypercar, Inc.

Private advanced technology development company focusing on “uncompromised” energy efficiency in automotive design

Design, engineering, and technology development and validation for OEMs and Tier I and II suppliers

Core competencies:

Skunk Works based, production oriented whole system product development

Advanced composite structure design and production solutions

Vehicle level digital integration and energy management

Products:

IP development, validation, and transfer

Applications engineering services: includes programs to develop, validate, produce and license whole vehicle and system-level production innovations

Collaborative whole-vehicle and system level production opportunities via JV’s or strategic partnerships

Team:

committed, experienced, high-performance individuals

Skunk Works ® development process merged with best practice of automotive, aerospace, and motorsport experience

system efficiency and technology

Reduce platform loads:

Mass/inertia

Thermal loads

Aerodynamic drag

Rolling resistance

Power transmission efficiency

New applications of technologies:

Advanced composite structure

Hybrid-electric drive

Electronics & software intensive control

Efficient suspension, propulsion, and accessory technologies

START FROM A CLEAN SHEET AND OPTIMIZE THE VEHICLE AS A SYSTEM Must consider complete production and overhead costs as well as cradle to grave costs to uncover practical solutions Then provide required energy in an efficient, clean, and cost-effective manner

creating the team

Unique Synthesis of Expertise

Best practice aerospace systems-engineering

Skunk Works breakthrough product development

Right-the-first-time design practice

Entrepreneurial spirit & motorsport heritage

Rigor of high-volume auto industry

Entrepreneurial spirit & motorsport heritage

creating the revolution

summary of the Revolution

Breakthrough Performance

Matches or beats conventional platforms in style, comfort, performance, and safety

99 mpg equivalent on gaseous Hydrogen fuel

Zero emissions

Cost competitive in a variety of variants near term or longer term

It is desirable by any measure

Platform-based design, illustrated by a mid-size crossover vehicle for Gen-X/Gen-Y drivers with active outdoor lifestyles

Many performance parameters influenced by Fleet requirements

Breakthrough Design & Manufacturing

Flexible platform-based vehicle design

Powerful onboard information network w/ fault tolerant power supply & distribution

Brake, power, traction, and steer-by-wire controls

Integrated aerodynamic design elements

Low accessory, heating, and cooling loads

Innovative vehicle assembly ideal for niche variants

the Revolution…

vehicle attributes Comfortably seats five 95% adults Can ascend a 44% grade with 1/2-ton payload 13.0 seconds 8.3 seconds A B 18 miles = 1 Gallon A B 99 miles = 1 Gallon 99 20 18 56 8.3 9.0 8.4 13 330 320 340 NA SULEV NA NA ULEV 1.96 2.1 2.3 NA 857 1832 1873 1330 460 466 408 NA 4564 4580 4843 4217 1830 1815 1783 1746 1548 1548 1719 1589 = 1873 kg lotta mass lotta mass lotta mass lotta mass = 857 kg noso much mass noso much mass 44 NA NA NA .26 .36 .43 .27 Ford Explorer Revolution Ford Escape Revolution Emits only hot water vapor H 2 O H 2 O H 2 O H 2 O H 2 O H 2 O H 2 O H 2 O H 2 O H 2 O H 2 H 2 H 2 H 2 H 2 H 2 H 2 H 2 H 2 H 2

package/configuration 35 kw Fuel Cell 5 ksi Hydrogen tanks 35 kw Load leveling NmH batteries Motors for each wheel 25kw fronts 10kw rears Power converter Adaptive suspension HVAC Composite suspension Thermal Management

vehicle information management and control: VIMaCS

Central “nervous system”

Customizable, plug-in electronics and seamless software-based upgrades

Intuitive, easily customizable user interface

Integrated intervention and distraction avoidance features and ergonomics

Advanced on-board and remote diagnostics

vehicle dynamics

All-wheel digital traction, stability, and braking

Upper Wishbone Front Subframe Front Knuckle Lower Wishbone Rear Trailing Arm

occupant environment

weight assessment Hypercar, Inc. Confidential and Proprietary Information

design team in action

the advanced composite solution

advanced composites SOTA Need is for stiffness and stability, energy management and load paths, NOT necessarily strength Stiffness (lbs/in 2 x 10 6 ) Density (lbs/in 3 x 10 - 2 ) Raw Matl . Cost ($/lb) Stiffness (lbs/in 2 x 10 6 ) Density (lbs/in 3 x 10 - 2 ) Raw Matl . Cost ($/lb) 0 100 200 300 400 500 600 700 800 900 Dry Tow RTD Rod RTD Uni 220F Dry Uni RT Wet Uni 220F Wet Uni RTD Quasi 220F Wet Quasi RTD OHT 220F Wet OHT 200 F 7075 Sheet Strength (ksi)

by design Built in reverse order to conventional vehicle Integrated side intrusion beam and hardware cassette incorporating hinges, latches, and window mechanisms Door inner panel doubles as interior trim surface with add on FMVSS padding where required Exterior skin is self-colored, easily removable, damage tolerant, and swaged for stability Door inner incorporates arm rests for controls Door pocket is formed by applying a front piece to the door inner Energy absorbing foam inserts S1 S2 S3 S4 B1 B2 B3 B4 B5 C3 C2 C1 S5 B6 B1 B2 B3 B4 B5 B6

structural analysis Crash Energy Management and Repairability Speed: 6 Mph 15 Mph 35 Mph > 35 Mph Damage: Deformation of bumper Bumper and beam destroyed Subframe destroyed Safety cell damage occurs Repair: Self repairing, no damage Replace bumper system and heat exchangers Replace complete subframe Impractical per convention

Thank you!