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Crashworthy Electric Car Body Design


New energy vehicles can have totally new structural layouts. This has great potential for the lightweight design. But there are also tremendous challenges considering the battery safety and battery containment. Here, numerical methods can support the development process. But, in order to support the development process with these CAE concepts and optimization strategies, it is very important to have knowledge on car body design and functional layout. This seminar will cover the crashworthiness knowledge for the design of electric car body. After the introduction in crash behavior fundamentals and the design principles, the important knowledge for the crash simulation of electric cars will be highlighted. The main chapter is on the technical implementation. The seminar ends with the description of the mathematical optimization methods for the crash development.

Course Contents

  • Fundamental mechanics of crash events
    • Accelerations during collisions
    • Structural loading during collisions
    • Examination of real crash events
    • Stability problems
    • Plasticity
  • Design principles for electric car body design
    • Functional based design
    • Car body structures
    • Battery structures for vehicles
  • Crash Simulation of electric car body design
    • Introduction in crash simulation
    • Finite element model generation of car bodies
    • Finite element analysis with explicit Methods
    • Examples
  • Technical implementation of safety measures
    • Energy absorbing members
    • Car bodies
    • Battery safety
    • Battery containment possibilities
    • Occupant safety systems
    • Post crash considering battery behavior
  • Using mathematical optimization in the development process
    • Introduction
    • Global mathematical tools
    • Optimization software
    • Optimization strategies
    • Scattering of variables
    • Shape variations and optimization
    • Topology variations and optimization

Prof. Dr.-Ing. Axel Schumacher
University of Wuppertal

Schumacher Prof. Dr.-Ing. Axel Schumacher studied mechanical engineering at the universities of Duisburg and Aachen. He received his doctorate on structural optimization from the University of Siegen. Following research projects for Airbus were focused on the optimization of aircraft structures. Thereafter he worked in the CAE methods development department of Adam Opel AG as project leader for structural optimization. From 2003 - 2012 he was a professor at the University of Applied Sciences in Hamburg and taught structural design, passive safety and structural optimization. Since 2012 he has been professor at the University of Wuppertal, where he holds the chair for optimization of mechanical structures.

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This course is available as an in-house seminar. The trainer comes to your site - you save travel expenses and travel time. Get an offer.

Your contact person

Dr. Dirk Ulrich
Phone.: 06023 - 96 40 - 66

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