Development of body structure concepts for electric vehicles using the topology optimization for global load pathfinding

Abstract

By the strict discussions regarding energy saving and the goal to reduce CO2, there is a keen demand for light designed automotive structures and the development of electric vehicles. To achieve these goals, a comprehensive method for urban vehicle concepts with electric powertrain and their necessary vehicle structures is presented. The dimensions and packaging of the presented vehicle is based on demands of a future urban vehicle with space for four occupants including baggage, steerable front system wheels and a rear axle including an electric powertrain. In the geometric design phase of the method the vehicle design space is analyzed for global load path with the help of topology optimization (OptiStruct). The load paths are then clustered into different shapes. Concepts for new body in white structures are derived from the results.