An aluminium-based concept of a co2-emissions saving sub compact car

Design,analysis,engineering,protobuild,testing of mid class
passenger car, aiming at 40% reduction on co2-emission in
the car's lifecycle. Main objectives: lightweight body
structure and efficient, clean driveline.

Objective: The development of a sub-compact car that reduces the emission of greenhouse gas CO2 during a car lifecycle by 40%; furthermore, meeting future legal exhaust gas emission Low Emission Vehicle - LEV), the passing noise requirements (71dBa), passive and active safety requirements, i.e. frontal offset side impact, enhanced total comfort requirements, i.e. climate, NVH (Noise, Vibration and Harshness), driveability and providing a large reduction in waste. Development: A body structure (1) using an aluminium space frame and structural panels with a high degree of integration which, in combination with vertical plastic hand-on panels results in a weight reduction -250 kg. reshaping and optimization (integration) of all mechanical components (2) (including in -250 mg) and a highly efficient and clean/light engine with low friction (3). a, b Body Concept: The actual space frame a1, a development of a junction/ bar/carrier structure, consists of semi-manufactured products via extrusion technology, in combination with rigidly joined horizontal aluminium sandwich panels a2 and junctions (castings, forgings or pressings) all joined by laser welds, adhesive bondings and clinching. The (complete) frame will be equipped with all the holes required in a drilling rig. This will avoid tolerance problems and facilitate an excellent fit of all hang-on parts a3. The front module b1, an assembly plate which forms a combination with the bumper skin, bumper structure, energy absorption systems, heat exchangers, ventilators, lighting and cable harness. The cockpit module b2, a non-handed, pre-assembled cockpit concept with climate installation, steering, pedal box with brake (ABS) booster, instrument, console, dashboard cover, airbag systems. The seats b3, multi-functional aluminium extrusion frame and rails single seats, with integrated belts. c Propulsion concept: The base engine concept c1 will be optimized in the areas, engine friction, friction and drive losses of the auxiliaries, general engine strucutres to acquire a weight and noise/vibration optimal system. The combustion and gas exchange of the predeveloped C-engine will be incorporated into a full scale packagable cylinder head c2 for vehicle installation, using variable low friction valve systems. Variable, lightweight engine air-fuel intake system with a maximum degree of integration of functions will result in the use of plastics c3. The control of the engine and exhaust gas after treatment system c4 in a car will take place using feedback and therefore self-learning/adaptive processes using very rapid, accurate and reliable sensors and actuators. d Chassis concept: Several components and systems must be developed to reduce total driveline losses, total vehicle weight and vehicle resistance (roll and air resistance) and to improve vehicle dynamics (active safety). e Electronics concept: Replacement of the traditional wiring systems by multiplexing class A. Class B multiplexing, communication between individual control units (ECUs) is increasing steadily. Improved diagnosis possibilities and optimal cooperation of individual control to achieve total vehicle control are the most important reasons for this. Innovation: This project is in its total approach, technical/scientific profundity and innovation absolutely new, aiming at low weight, high comfort level, low CO2, emissions at competitive cost level. In short, the integral approach with two main pillars, that is, aluminium space frame technology and a highly efficient drive source and furthermore, logical downsizing, based on a low total vehicle weight, make this a unique project.
Project ID: 
1 057
Start date: 
Project Duration: 
Project costs: 
13 290 000.00€
Technological Area: 
Market Area: 

Raising the productivity and competitiveness of European businesses through technology. Boosting national economies on the international market, and strengthening the basis for sustainable prosperity and employment.