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Systems Focused Product Development Of The Hypercar
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Systems Focused Product Development Of The Hypercar

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The Hypercar company and the Hypercar program are used as an example of how systems integration can be a focus and key enabler in challenging product development efforts

The Hypercar company and the Hypercar program are used as an example of how systems integration can be a focus and key enabler in challenging product development efforts

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Systems Focused Product Development Of The Hypercar Systems Focused Product Development Of The Hypercar Presentation Transcript

  • 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
  • Unique Synthesis of Expertise
    • Best practice aerospace systems-engineering
    • Entrepreneurial spirit & motorsport heritage
  • Unique Synthesis of Expertise
    • Best practice aerospace systems-engineering
    • 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!