DEVELOPMENT OF LIGHTWEIGHT STRUCTURAL COMPONENTS BASED ON LOW-COST PROCESSES FOR APPLICATION IN 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, which allow 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 caused by transport, combat the deterioration of air quality in cities, aim to minimize the 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 aligns with the 2 most common research and development areas in the transport sector to address these factors to some extent: action on electrified transport systems and the development of lightweight solutions (both for internal combustion engine vehicles and new electric vehicles). Similarly, it also seeks to provide solutions to the barriers that prevent 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 proposes to strategically combine, in certain elements, materials of different natures (thermoset and thermoplastic composite materials, cellular polymers, and steel), in such a way that the weight of the structures developed for a three-wheeled electric vehicle and for 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 summary, the proposed objectives will be achieved through the development of the following technological milestones:
- Application of multibody dynamic analysis to three-wheeled vehicles to determine their in-service behavior based on their interaction with the environment, in order to feed the vehicle redesign phase from a multi-material perspective.
- Use of lightweight materials such as high-strength steels, foams, and composites using multi-material designs and manufacturing and assembly technologies using structural adhesives that consider the design of joints according to the new materials introduced.
- Development of low-cost structural part manufacturing methodologies based on the thermoforming of medium-quality plastics with continuous fiber reinforcement, using plasma surface treatment to improve the interaction between both phases.
- Development of lightweight demonstrators for the 2 proposed case studies, which will allow the project’s developments to be validated in a relevant environment: a lightweight multi-material superstructure for buses and a new monocoque chassis concept composed of high-performance thermoset and thermoplastic composite parts, or a structural arm supporting the two rear wheels made of thermoset composite manufactured using out-of-autoclave (OOB) curing processes and reinforced areas, in the case of the three-wheeled vehicle.
- Definition of recycling methodologies and LCA analysis of multi-material structures, evaluating the environmental impact of the developed vehicles.
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.
CARROCERA 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 company specializing in thermoset matrix composite materials (TMCM) in combination 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 through liquid resin injection processes, such as RTM (resin transfer molding).
UNTHA IBÉRICA, a company specializing in recycling solutions.
In addition, the consortium includes the participation of the technology center AIMEN, 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.
In this second year, significant emphasis has been placed on activities related to the optimization of designs for the different case studies. Thus, considerable work has been done on redesigning the chassis and swingarm of the three-wheeled vehicle to refine the load specifications, enabling composite material dimensioning. Furthermore, work has been carried out on the bus superstructure, identifying and analyzing different lines of action with varying performance-weight-cost ratios. Finally, significant effort has been dedicated to fine-tuning manufacturing processes, with subsequent characterization of the composite materials thus produced. This campaign has included the study of the recyclability of the different polymer-based materials considered within the project framework. To this end, crushing studies of the different combinations under consideration have been carried out.
PROJECT FUNDING:
This LIGHTRANS project, part of the CONECTAPEME 2018 program, is financed by the Xunta de Galicia through the Axencia Galega de Innovación (GAIN) and with the support of the Consellería de Economía, Emprego e Industria, and is co-financed by ERDF funds within the framework of Axis 1 of the ERDF Galicia 2014-2020 operational program.
