Case study of simulation driven designed components in use for a

hydrogen-powered prototype vehicle

Agenda

• Aim: How we try to think before we build

• Introduction Team

• General Information

• Composites

• Topology Otimisation

• Aerodynamics

The Team

The Mission

33,5 kg light

Hydrogen fueled

603 km/m³Hydrogen => 1849 km/l gasoline => 3rd Place Shell Ecomarathon 2015

Continous development

Fuel Cell

t r

tCoolingWaterTank

H2 Tank

Radiator

Air Pump 2

Water Pump

Filter 1

Cut-Off ValveH2 Flow-Meter

Fuellcell

Air Pump 1

Temp. Sensor

Temp. Sensor

RhSensor

t rTemp. Sensor

RhSensor In In

Out Out

Manometer ManometerPressureReducer2bar

PressureReducer250mbar

V

MOSFET

Coil

Voltmeter

Voltmeter

Ampere-meter

A

V

CAP´s

Air

Hydrogen

Humid Air

Hot Water

t Temp. SensorBlowout Valve

ECU

Electric

Motor

Torque

Air

Air

Hydrogen

cold Water

Elec. Current

p p

HeatingJack

Heating Coil

Bottle Valve

Air

Purge Valve

Elec. Current

Live Telemetry

• Live data stream

• Preset options

• Average speed

• Visualisation online

Composites

• Easy Part for experimentation

• Hybrid: GFK Core CFK Cover Layer

• Easy load step

Measuring

• Eigenfrequenz analysis

• Spring mounted in car

Topology Optimisation

• Boundary conditions

• Load and deformation requirements

• Design follows topological optimization

Weight and stiffness

• Designed parts result with concrete loadpaths

• Inspiration for design process

• Productionally by additive manufacturing

• CFD - Simulation 25 km/h – 30 km/h

• Mutating the geometry

Aerodynamics

Aerodynamics

Aerodynamics

Aerodynamics

Aerodynamics

AerodynamicsSummary

• Status quo with covered front wheelsc * Ax = 0.040 m²

• New concept for completly covered front axlec * Ax = 0.065 m²

• Conclusion: Why build a new car? Let‘s get rid of the problematic sections and build new wheel covers.

• Collaboration with more faculties

• Comparision of different software tools

• Composites manufacturing and testing

Outlook