Experts: The key to the development of electric vehicles is lightweight

The General Coordinator of the Sino-German Automotive Lightweight Co-Development Center and the professor of the Tongji University, Mofan, told reporters in Braunschweig recently that the current bottleneck of the development of electric vehicles is under the conditions of not having mature infrastructure and not having fast enough charging methods. Is the problem of endurance, and lightweight can significantly improve the endurance of electric vehicles, automotive companies have paid widespread attention to this.


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At the 2015 Brunswick Global German Automotive Forum held in eastern Germany, Mofan briefed reporters on some features and trends of lightweight electric vehicles. He pointed out that lightweighting is a common technology that can be widely used in aerospace, rail transit, automotive, robotics and other fields. "As far as the automotive industry is concerned, pure electric vehicles achieve a battery life of more than 500 kilometers, and it is imperative to take a lighter route. The example of the pure electric concept vehicle, the Mission E, was released at the Frankfurt Motor Show this year."

Mo Fan believes that Chinese car companies can focus on magnesium alloys in light weight. “Magnesium alloys are one-third lighter than aluminum alloys, and China's magnesium reserves are abundant, and its potential for future development is huge.”

He also revealed that the relevant Chinese and German agencies plan to establish a joint research and development center for lightweight vehicles in Dresden, which will have the overall capability from scientific research to industrialization and is expected to become a new bright spot for Sino-German scientific and technological cooperation.

Mofan told reporters that there are three main technical methods for lightweighting automobiles: First, the structural components are mainly metal, reinforced with carbon fiber and composite materials, and they can reduce weight by 10% to 20%. This technology has been used by many vehicles. The adoption of enterprises is also the main method of lightweighting traditional fuel vehicles.

Second, the upper part of the car body is made of carbon fiber and other composite materials. The chassis is made of aluminum alloy. This technology can make the proportion of the composite material in the whole vehicle material close to 50%, and the weight loss effect is up to 30%. BMW's first electric car has adopted this technology.

The third is the use of a variety of materials such as metal composite materials, composite materials, a higher proportion of materials, weight reduction effect of up to 50%, on behalf of the model is Dresden University of Technology Institute of lightweight and material technology, Germany, Saxony lightweight The InEco, an ultra-light-weight, four-seat electric car jointly developed by the Center and ThyssenKrupp.

Mofan told reporters that vehicle weight reduction is not only a lightweight body, but also includes transmission equipment and batteries. For example, to increase the unit volume of battery capacity to achieve lightweight, currently this technology can be engineered. InEco's electric vehicles use 57% of the composite materials, and the drive and battery systems are also lightweight. The car's full-life period can save energy by 28%. At the same time, it brings deep innovation in the production line.

Mo Fan said that light weight and new materials are inseparable. The future of lightweight electric vehicles involves five major materials: carbon fiber reinforced thermoplastics, high-strength steels, carbon fiber reinforced thermosets, aluminum alloys, and magnesium alloys. The use of these materials should be comprehensively considered in terms of cost, connection with metals, repair and recycling. Among them, high-strength steel is currently the most cost-effective.

“From the point of view of being close to the market, high-strength steel is very ideal, and lightweighting should not blindly pursue material 'tall', and the result of high cost is difficult to promote and apply,” said Mo Fan.


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