JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 52

urban vehicle
Specifications

The following specifications were defined for
the vehicle:
- Type approval: L5 tricycle > 45km/h
(no power limit, no speed limit)
- Safety philosophy: 2 main specifications
based on the M1 regulation:
- Front impact
- Side & pole impact
- 3 seats for 3 adults: roomier than a Smart at

only 10 cm longer
- Ambitious weight target: <700 kg, including
130 kg of battery
- 20 kW (30 kW peak) electric powertrain
- Maximum speed: 110 km/h
- Acceleration/mid-range acceleration level:
same as an ICE powered Citroën C1 or
Peugeot 107
- 100 km range on an MVEG standard cycle

Fig.7 : Pole impact simulation

The body structure performance was
evaluated under static and dynamic
conditions: acoustics, ride & handling
behaviour, and crash (front impact, side
and pole impact).
The first design-to-cost evaluation was
performed.

Fig.4 : Body structure breakdown

structure with an aluminium space-frame
front unit, to be manufactured using the
RTM process.
A one-shot infusion process was selected
for the prototype. The inner and outer
panels were produced on a 120 kg/m3
polyurethane foam core (SPF120 milled
blocks + balsa). Bi-directional glass fibre
(0°/90° 570 g/m²), Interglas 2/2 twill
weave glass (280 g/m²) and Soric LRC
non-woven (2 mm) were used as reinforcements,
together with a Dion Impact
9102 epoxy vinylester resin. The parts
were bonded with SAF 30-45 MMA.
The composite body structure includes
8 main parts and weighs 80 kg with
glass fibre, or 50 kg with carbon fibre,
compared with a 120 kg steel birdcage
The outer panels are made of ABS
PMMA, while the side and rear glazing
uses PMMA. The windscreen is made of
laminated glass.

Fig.5 : Assembly scheme

module, the rear suspension, the battery
and the seats. The static and dynamic
properties of the composite materials
were assessed as part of the calculation
and design optimization process. Highspeed material behaviour tests (crash,
high-speed impact) were required for the
dynamic properties.

Manufacturing
The parts were manufactured by oneshot
infusion moulding, using an outer
fabric (in the mould), a foam core and an
inner fabric.

Results
The first design step focused on the
number and functional grouping of parts,
on style integration and on the interior
and exterior design. Functional interfaces
were developed for the front end

Fig. 6: Front impact simulation

52 jec composites magazine / No82 July 2013

Fig. 8: Infusion



JEC COMPOSITES MAGAZINE - Issue #82 - July 2013

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #82 - July 2013

Cover
Edito
Point of view > quality & service
Contents
Agenda of Events
COMPANY & BUSINESS In Brief
APPLICATIONS
Buses
UAV
Offshore
MARKET
Bio-resins
China
FEATURE AUTOMOTIVE
Manufacturing
Reinforcement
Body panel
Suspension
Wishbone
Seats
Beam
Urban vehicle
RESEARCH & DEVELOPMENT 3D fabric
TECHNOLOGY & INNOVATIONS
RTM
RTM
Thermoplastic
Index
In the world
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - Cover
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 2
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - Edito
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - Point of view > quality & service
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 5
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - Contents
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 7
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - Agenda of Events
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 9
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - COMPANY & BUSINESS In Brief
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 11
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 12
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - Ad1
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - Ad2
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - Buses
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 14
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - UAV
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - Offshore
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 17
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - Bio-resins
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 19
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 20
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 21
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - China
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 23
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 24
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - Manufacturing
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 26
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 27
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 28
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 29
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 30
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 31
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 32
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - Reinforcement
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 34
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 35
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - Body panel
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 37
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - Suspension
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 39
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - Wishbone
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 41
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 42
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - Seats
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 44
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 45
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 46
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - Beam
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 48
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 49
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 50
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - Urban vehicle
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 52
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 53
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 54
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - RESEARCH & DEVELOPMENT 3D fabric
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 56
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 57
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 58
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 59
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 60
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - RTM
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 62
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - RTM
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - Thermoplastic
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - Index
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - In the world
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 67
JEC COMPOSITES MAGAZINE - Issue #82 - July 2013 - 68
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