Chassis Strength Evaluation and Rollover Analysis of a Single Seat Electric Car

Abstract

This thesis work is the part of project “EDV (electric demonstration vehicle)” at Volvo group trucks technology, Mechatronics and Software division, which aims at building a single seat electric car. The car will later, primary, be used for function development. In this thesis, mass of the vehicle and the center of gravity position of the static vehicle are estimated and are used to perform the chassis strength analysis and rollover analysis of the vehicle. For chassis strength analysis, three frame variants are analyzed with various beam cross sections and frame features such as fillets and gussets to optimize for torsional stiffness, bending stiffness, stress generated and weight. For steady state rollover analysis, the vehicle is tested for rollover propensity on various maneuver conditions, road friction conditions, bank angles and vehicle property such as center of gravity location of the vehicle. Though, the results of this thesis work pertain to a specific single seat electric car, but, the results are extrapolated to provide a general overview. Beam cross sections and structures of chassis are proposed in the chapter chassis strength evaluation. Here, both analytical model and finite element analysis models are presented. The results of rollover analysis pertain to the limitations of the vehicle in terms of road friction, possible maneuver proportions, possible speed limits, bank angles and vehicle property such as center of gravity height.