Performance Evaluation of Chassis System for Converted Hybrid Electric Vehicle 2019-26-0260
The technology development in automobiles is progressing towards
providing smarter vehicles with increased efficiency and reduced
emission. To cater this need, Electric Vehicles (EV) and Hybrid
Electric Vehicles (HEV) are slowly thriving in Indian roads.
Conversion of existing IC engine powered vehicle to HEV reduces
complication in new vehicle development and also results in
vehicles with increased efficiency and reduced emission. In order
to convert the Conventional Vehicle to Hybrid Electric Vehicle,
drive from electric motor was coupled with existing driveline by
modifying mechanical systems suitably. Hybrid vehicle includes
systems such as electric motors, inverters, high-voltage batteries
and electronic control units, which are mounted in chassis members.
Being a major load carrying member, any modifications in chassis
system may affect the performance of vehicle, therefore it is
necessary to evaluate the modified design of chassis members.
Finite Element (FE) model was built for existing chassis system.
The FE modelling was carried with validated Modelling techniques,
which gave good correlation with physical testing results. Modal
analysis of chassis was carried out to find out the fundamental
frequency and its harmonics. When the vehicle ply on road with
different loading conditions, the chassis is subjected to twist and
bending loads. To capture this, bending stiffness and torsional
stiffness of the chassis system were determined using simulation.
Apart from this static strength analysis was carried for Braking,
Cornering and Bump Loads. Vibration, Stiffness & Strength
Analysis of chassis system was evaluated to ensure the performance
of the chassis system. Results from these analysis were set as a
benchmark target. Initially Subsystem level Strength Analysis have
been carried out for newly added components, to ensure that they
are not failing in static loading conditions. The Modified Chassis
system meeting the functional requirements for converting into HEV,
was again analysed for modal frequencies, stiffness and strength
load cases. The results were in line with target values. Rear
impact analysis was carried to in existing vehicle to check whether
any deformation affecting the battery package. However, it was
found that there was no deformation in battery mounting location.
This boosts the confidence to implement the changes in chassis
system of proto vehicle. With the validated changes in chassis
members, Proto Vehicle have been built and it was tested for its
Ravindra Kumar, Rajesh H, Mayur Shimpi
Automotive Research Association of India
Symposium on International Automotive Technology 2019