DEVELOPMENT OF LIGHTWEIGHT STRUCTURAL COMPONENTS BASED ON LOW-COST PROCESSES FOR APPLICATION IN ECO-EFFICIENT TRANSPORTATION
ECO-EFFICIENT TRANSPORTATION (IN852A 2018/81)
The main objective of the LIGHTRANS project is the design and development of lightweight multi-material structures, through the development of optimized and low-cost manufacturing and joining processes, for their application in eco-efficient road transport vehicles. Specifically, the superstructure of an eco-efficient bus and a three-wheeled electric vehicle will be redesigned.
The need for initiatives like LIGHTRANS is based on the search for global efficient solutions to reduce CO2 emissions from transportation, combat air quality deterioration in cities, minimize the impact on ecosystems essential for life on the planet, and achieve less dependence on oil reserves in the automotive sector.
In this regard, the project aligns with the two most common research and development areas in the transport sector to address these factors to some extent: focusing on electrified transport systems and developing lightweight solutions (for both internal combustion engine vehicles and new electric vehicles). Similarly, it also aims to provide solutions to the barriers that hinder the wider use of polymer matrix composite materials (PMCs) in the transport sector (limited manufacturing rates, high cost of materials and processes when maximizing mechanical performance, or difficulties in recycling/repair).
Based on this background, LIGHTRANS proposes to strategically combine, in certain elements, materials of different natures (thermoset and thermoplastic composite materials, cellular polymers, and steel), so that the weight of the structures developed for a three-wheeled electric vehicle and an eco-efficient bus is minimized, their structural performance is maximized, there is a good economic balance, and they minimize the vehicle’s environmental impact.
In this third annual period 2020, the development of activities related to the optimization of multi-material designs for the different case studies has continued, thus completing the redesign of the chassis and swingarm for the three-wheeled vehicle and the lightweight bus superstructure. Similarly, various molds and tooling necessary for the development of prototype components have been designed and manufactured, and structural nodes for the bus superstructure have been developed and characterized. Furthermore, it should be noted that the assembly of the constituent components of the final lightweight bus structures has begun, and the validation methods for the representative section of the bus superstructure have been defined through a custom test, after which the obtained deformation will be measured. In the case of the multi-material three-wheeled vehicle, the assembly of the demonstrator has commenced. Finally, it should be highlighted that in parallel to the definition of multi-material solutions, the assessment of the environmental impact of the designed structures, as well as corresponding recyclability studies, has been ongoing.
LIGHTRANS CONSORTIUM
To achieve the ambitious objectives set, LIGHTRANS brings together six companies with complementary profiles, covering the entire value chain of the proposed activities:
VMS AUTOMOTIVE, leader of the LIGHTRANS project, end-user, and developer of an innovative 100% electric three-wheeled vehicle.
CARROCERÍAS CASTROSUA, end-user of the project, manufacturer of bus and coach bodies, and a pioneer in the development of hybrid propulsion systems.
RESINAS CASTRO, as a specialist company in thermoset matrix composite materials (MCTE) combined with high-performance fibers and out-of-autoclave manufacturing processes.
ALEACIONES LIGERAS Y PLÁSTICOS, a company specializing in thermoplastic materials and their manufacturing processes (thermoforming, injection), galvanic protective coatings, and cellular material injection.
POLIÉSTERES SOBRAL, a company expert in processing thermoset matrix composite materials using liquid resin injection processes, such as RTM (resin transfer molding).
UNTHA IBÉRICA, a company specializing in recycling solutions.
Additionally, the consortium includes the participation of the AIMEN Technology Center, an entity with extensive experience in the design, manufacturing, and characterization of composite and multi-material components, as well as in the study of dissimilar joints and the optimization of manufacturing processes; and the Mechanical Engineering Laboratory (LIM) of the University of A Coruña, an expert in the study of multibody system dynamics applied to automotive engineering.
