Electric Mobility

Alexandre Pinto, Senior Director, Mubea China

Electric Mobility has leveled up the bar in terms of energy efficiency and performance standards as the next generation of electric vehicles has been developed. `

While We still see electric cars in the market which are derivatives of their internal combustion engine platforms, there is a strong trend towards dedicated platforms for electric mobility since recent years, and mainly newcomers with disruptive concepts and a common platform strategy that can couple to several different models with the lowest investment as possible.

Electric mobility, due to its simplicity and systems high integration possibilities has driven the industry to develop new solutions from what We have observed during the last 50 years at least.

In terms of platform, those vehicles have a much lower center of gravity, higher bending, and torsional stiffness values mainly driven by the high rigidity of battery packages, 50/50 mas distribution, and much lower load transfer in braking and cornering, which drives to different chassis design perspectives.

Added to this mechanical aspect, high artificial intelligence integration leads to much higher performance possibilities like active torque vectoring highly integrating e-motors, brakes, and steering systems which is key to reach higher levels of ride comfort mainly on autonomous driving modes.

We from Mubea, following our main strategy in delivering innovative, high-performance, and lightweight solutions, have invested heavily to be the best development partner to our customers.

To address the major roadblock on e-mobility which is to maximize range capacity, we focus on lightweight and disruptive designs to increase battery-package space and range.

Tailored Rolled blank steel components can, thru reduction of steel wall thickness in regions of lower stress levels in stamped body parts and tubes, are the best cost/weight ratio solution driving to up to 20 percent weight reduction and will be an alternative lower-cost solution to aluminum battery cases at a very similar weight and an enabler to trending cell to chassis concepts.

"Added to the mechanical aspect, high artificial intelligence integration leads to much higher performance possibilities like active torque vectoring with full integration of e-motors, brakes, steering systems and ultra-light weight solutions to maximize efficiency"

Composite solutions are as well strongly developed to reduce weight. Body structures in carbon fiber, full carbon fiber anti-roll bar systems, wheels, hybrid alloy/carbon fiber wheels reduce weight by up to 50 percent and can considerably increase crash performance and stiffness of body structure and battery systems.

More cost-efficient composite solutions are as well available, such as glass fiber reinforced plastic parts. Leaf springs reduce weight by 50 percent, battery packs underbody protection plates reduce weight by 35 percent compared to aluminum solutions at a cost below 4 EUR/kg.

Transversal leaf spring suspension designs can combine spring and anti-roll bar functions but as well substitute complete suspension links. Potential weight reduction is of 15Kgs compared to a similar multi-link design and battery pack increase up to 10 percent.

New technologies are as well available on battery cells cooling plates, made in warm rolling bonded and blow process, which eliminates the necessity of forming tools and shows the best cost efficiency in the market.

Mubea E-Rotor shaft systems allow more space-efficient installation resulting in higher motors speeds and motor efficiency (range).

In terms of vehicle dynamics solutions, Active or Adaptive stabilizer bar systems are key to provide electric cars Ride and Handling flexibility as it allows vehicles to increase roll stiffness high roll velocities while it reduces roll stiffness in straight-ahead driving bringing a new level of passenger comfort to passengers while keeping upper handling performance during cornering.

We understand lightweight fully integrated design solutions will be key to enhance new mobility performance to the next level so as a major driver to individual air mobility vehicles and Mubea intends to be a key partner to its customers.