DEVELOPMENT OF LIGHTWEIGHT STRUCTURAL COMPONENTS BASED ON LOW-COST PROCESSES FOR THEIR APPLICATION IN ECO-EFFICIENT TRANSPORTATION
(IN852A 2018/81)
The main objective of the LIGHTRANS project has been 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 has been redesigned.
The need for initiatives like LIGHTRANS is based on the search for global efficient solutions to reduce CO2 emissions from transportation, combat the deterioration of air quality in cities, aim to minimize the polluting effects on ecosystems essential for life on the planet, and achieve less dependence on oil reserves in the automotive sector.
In this regard, the project has aligned 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 has also sought to provide solutions to the barriers that hinder the more extensive use of polymer matrix composite materials (PMCs) in the transport sector (limited manufacturing cadence, high cost of materials and processes when maximizing mechanical performance, or difficulties in recycling/repair).
Based on this background, LIGHTRANS has proposed to strategically combine, in certain elements, materials of different natures (thermoset and thermoplastic composites, cellular polymers, and steel), so that the weight of the structures developed for a three-wheeled electric vehicle and an eco-efficient bus is minimal, their structural performance is maximum, there is a good economic balance, and they minimize the environmental impact of the vehicle.
In this fourth and final annual report for 2021, the assembly work of the constituent components of the final lightweight bus structures has been completed, and validation activities for a representative section of the bus superstructure have been carried out through a custom test, quantifying the deformation obtained. In the case study of the three-wheeled vehicle with a multi-material solution, the assembly of the demonstrator has been completed, and in-service validation tests have been conducted. Finally, it should be noted that in parallel to the manufacturing and validation tests of the multi-material solutions, and leveraging the conclusions obtained, the environmental impact assessment analyses of the designed structures, as well as the corresponding recyclability studies, have been completed.
LIGHTRANS CONSORTIUM
To achieve the ambitious objectives set, LIGHTRANS has brought 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 (TMCS) combined with high-performance fibers and out-of-autoclave manufacturing processes.
ALEACIONES LIGERAS Y PLÁSTICOS (ALYP), 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.
In addition, the consortium has had 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 with the Mechanical Engineering Laboratory (LIM) of the University of A Coruña, an expert in the study of multibody system dynamics applied to automotive.
PROJECT FUNDING:
This LIGHTRANS project, part of the CONECTAPEME 2018 program, is funded by the Xunta de Galicia through the Axencia Galega de Innovación (GAIN) and the support of the Consellería de Economía, Emprego e Industria, and is co-financed by ERDF funds under Axis 1 of the ERDF Galicia 2014-2020 operational program.
