JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 31

E-LFT Process integrates the centre-belt anchorage along with standardized child-seat anchorage points (Toptether and Isofix). The concept models underwent intensive simulations and optimizations at an early stage. A comparison with previous simulations and parts [2, 3] demonstrated that integration into the overall system would generate satisfactory results. The crash tests showed that an explicit simulation (LSDyna) of the overall system would make it possible to reach the maximum possible agreement (Figure 3). More information Weber Fibertech is a division of Weber Automotive. A supplier to the automotive industry, Weber entered into the fibre reinforced plastics (FRP) industry in 1998. Today, the company is a high-end supplier of motor blocks, crankshafts, entire engines and fibre-reinforced-plastic components. The many positive experiences gained with the high loading capacity of E-LFT parts as well as the numerically-simulated material behaviour led to the idea of developing a fully load-bearing composite body structure. Fully utilizing the technology’s strengths would make it possible to produce a composite body structure in high volumes. The single-step process, inexpensive starting materials, high degree of automation and drastically reduced number of parts will result in an economic advantage. Furthermore, this economic efficiency is significantly increased by the high degree of functional integration. Fig. 3: Test series in US-NCAP conditions: layout, simulation and prototype testing The tests were carried out under US-NCAP conditions s(v = 60 km/h, a = 45 g). The centre belt was loaded with a 95% hybrid III male dummy, while two 18-kg cubes, positioned in the trunk, served to simulate baggage. The static tensile belt test (ECE R14 + 20% reserve) requires that the belt withstands a 20 kN tensile force applied for 10 s. The prototypes passed this test and all the other required tests. The rear seat backrests are 20–30% lighter than the original metal versions. Design The design was based on an in-house design study for a compact car with a metallic front structure and an E-LFT shell (Figure 5). The floor has a double-shell construction that meets the torsional and flexural rigidity requirements. The new study concerns a two-seater roadster. New simulation methods with integrated delamination and failure models make for a much improved design. Fig. 5: Initial concept study for an E-LFT compact car for five passengers Fig. 4: Weber Fibertech series production plant in Markdorf, Germany Composite body structure concept There is one undisputed fact in all of today’s controversial debates about new drives, alternative forms of energy and energy-efficient models: the smaller the moving mass, the less energy is necessary. In other words, with a significantly lower vehicle weight, even today's engines would consume significantly fewer resources. A somewhat ambitious example would be to radically reduce the weight of a modern new car from 1,300 kg to 800 kg. Given the current savings of 0.3– 0.5 l/100 km [4] (depending on the calculation method) for every 100 kg of weight reduction, fuel savings would be 1.5– 2.5 l/100 km for a modern gasoline engine. The passenger cell comprises several E-LFT shell elements made of PP-GF . The size and the double-shell construction dictate that the structure is subdivided into several segments, as shown in Figure 6. The limitations imposed concern the press size, press force and material output from the Fig. 6: Part segmentation of direct processing plant. The shape of the passenger cell the segments provides enough room for the pedals, air conditioning, steering, electrics and additional safety equipment (airbags). In some cases, functions can also be directly integrated. The individual segments are joined to the final composite monocoque. No53 November - December 2009 / jec composites magazine

JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009

Cover
Editorial
Contents
NEWS WORLDWIDE - Companies
 - Advance FRP: Choosing success
 - Agenda of events
 - Equipment: Mould
BUSINESS
 - Market survey
 - Trends
 - Niche market
FEATURE - AUTOMOTIVE
 - Thermoplastics
 - Nanotubes
 - E-LFT process
 - High-temperature
 - Coating
 - Software
 - Process
USERS' PLATFORM
 - Composites in the world
 - Successful partners
 - Application
KNOW-HOW
 - Process
 - Localized heating
 - Process
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - Cover
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 2
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - Editorial
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 4
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 5
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - Contents
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 7
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - NEWS WORLDWIDE - Companies
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 9
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 -  - Advance FRP: Choosing success
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 11
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 -  - Agenda of events
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 13
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 -  - Equipment: Mould
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - BUSINESS
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 -  - Market survey
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 -  - Trends
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 -  - Niche market
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 19
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 20
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - FEATURE - AUTOMOTIVE
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 22
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 23
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 -  - Thermoplastics
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 25
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 26
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 27
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 -  - Nanotubes
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 29
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 -  - E-LFT process
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 31
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 32
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 -  - High-temperature
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 34
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 35
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 -  - Coating
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 37
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 -  - Software
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 39
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 -  - Process
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 41
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 42
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - Pub
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - Pub
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - USERS' PLATFORM
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 -  - Composites in the world
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 45
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 -  - Successful partners
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 47
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 -  - Application
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 49
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 50
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - KNOW-HOW
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 -  - Process
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 53
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 -  - Localized heating
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 55
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 56
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 -  - Process
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 58
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 59
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 60
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