Lotuis Engiineering

The New Lotus Evora Structure Strateqic Ouestions in Car Body Enqineerinq

Versati le Veh ~c~e Arch~tect

Contents of Presentation

• Lc)tJUs Product 'Overvie,w

• AlumiiniUlm Structure

M,on utact Lire

• C.AE ,Overv'iew

• Chassis A.s;s,e,m,bly

• Body As,semblly

• EV SuiitabiUty

Lotuis Engiineering

ILotus Product Overview

Production vol ume ru nning at 3500 unitsly',e,ar, aU usa Elise plattorm

ii, IE,lise

., [E"x~g,e

• Europa. S

., ,2ellev,sn

,3td party rnanutaclu ring ., Tesla

Lotus Europa S

Lotus ,2'eleven

Posi'tioning I. ILotus IProducts Plla.n

Ibhpl10n

350

e

;

m300

10,,;,

... J::

C),

.-

m 250 !:

~

CD 200

==

e

D.

160

-

Simlple and clear pro,duc1 -. .. --

range strategy: ... .. ... __ .. _".'._

_ .. ~ IEspll'llt

---

---

--

11. -. Evora

... Ext e -

• Espr~t iis a "'high status" purchase

• EssentiiaJ brand iimage bu~~der

Ellj~

• IE·vora is I ar'gl,er , more refi ned, rnoresu Itable than Ellise for every day US'9' but still pu re

• Logli'cal next step for rnatu ring Ellhs,e' owners

., EI ise ls the basic entry ~,e:vell sports car, focused, pure, fun

Lot:us Englln€N3rlng

EvoralElise .. VelhioleDimlenlsio,ns

,~

2575

=¥O~=, 43414 "SSg

DVIIIITIII'

1148,:

-1 'f 't21!1i' +'10'1

Compared to base Porsche Oarrera, Lotus IEv'ora ~ength is 85mm shorter I' height is 86,.5mlm Iless'I' width ls 4,2mm 'glreater..,

Lot:us Engll1ns,sring

Evora P,8ckage • Centerlilne' Sectio,n

Ke- - .Attriibul.es

- y -- - - --

.. Mlid-engined2 pll us z

• 99th perceniiille male front occupant, !lUll peroentile female rear

• Wheelbase is just ,2:75mm gre.ater than Elise! but this has enabled 7Smm more rearwardsest adljustmlent, rear occupants and an extra bank ot cylrinders of the va engine

Uniits per weelk prtorte crunch

2000

11000

500

250

125

50

25

5

2500/yr (Lotus Evora)

100,OOOlyr (Audi AS Saloon)

15.!OOO/yr (Audi A4 Convertllblle)

4000/yr (Audl IRB)

Lotus

Lot:us Englln€N3rlng

Audii

Lamborg hiin i

Bentlley

Ellis,s structure has:

• S~iffn@;s:s

• Durability'

.' Light weiig.lht

• Orashworfhlness

• Aceu r.acy

,. Low ~nvest:me!n1

<ii' LoW' piece cost

E.llisestructure lacks:

•. P;a.ck1\ge ,eUioie,ncy

• Rep,a.inlbiliitiy

tI· COrilt~ mporary NV'H

.' Si~e variation capabmty

IRed - Ellis:e tub Green - Evora tub

- Structu res a.lliig ned in X. at front bu lkhaad

-Evora silll hieight 24mlm lower than EUs.e

Evora S gnl f cant Str1ulc'tulral C,omponlents

IR,ear su bframe

Seat belli anchorage frame

.. MIG weldledllE,355 steel

• Reacts roof crush

Tub

• Bonded and riivetited

.. Allu rnlnlu m extrusions 6060~35, 20 profiles

<I ,Alluminiium sheet 5754

• IS,onded and

• A~u mini urn extrusions 6060-3c5, ,8 pr,of~lles ., A~u miini ulm sheet 5754

Lot:us Englln€N3rlng

Coupe 26

StiHness Torsion

(with root and IkNm/deg

screen)

• Spot 1M I G wl~~lded Tenform XIFSOO

Bending kN/mm

screen su rround, roof

- - --- - - - - ,'I --

and Ibodysildle (not ,sho,wn)

• Oomposite RrM

Roadster 14

10.5

Lotuis Engiineering

Lotus Evora Aluminium Structure Mlan ufactu re

Process flow

• Extru9,iion mach in~ng, sheet component fabric,ati,on .' Anodiising

,ii Adlhe~silve application

• Sub as,semlbly - as required for vall um'9' and ,aCOE!'SS .' Ma~n a.ssemlbly

• SeaUngl ,-, tocal sealiing against watsr, air and nclss iingnes's

• Re'lmovall 'fromfrtxture

• Curl ng 0,' adhl9sive- 180 degrees, for 20 minutes

• ~ nspectton

Design .. Dat:luml Strat:egy

3

Example Of 8~2~11 location of part to miltligate' extrusion tw~st and stra~glhtness dev~at~on

)-K

Lot:us Englln€N3rlng

., Four master datum locafions on underside of mla~11 slructu re

• AIIII other components datumledfrromthes,e locations

• Tolerance mlanagelment ,of

m achned extrusions ensures hardpo~nt accuracy

1

S de M,ember Form In9 Process

Extrusion notched as straligh~ lengtlh, lower wall I h~dt intact

., ,Avo~ds costlly stretch forml toof ngl ., Heat treatment process

.. ~ mproves tolerances I

.. ~ ncreases occupant packaqa space

P art formed and tack welded then finish mlach~ned prior 'to anod~sli ngl

Lot:us Englln€N3rlng

· -

Chassis ad hesilve platten ~made from laser cut. and folldGld· sheet to avoid high. t010liing cost

315
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0 BeNlD IL..INE THIICKNIESS I STRENGTH ANID ,ST~IFFINESS liN SHIEAR

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1 .. 2 eONDUNIE TH1CKNESS

2.,4

Lot:us Englln€N3rlng

PeelPerfo,rmance

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I 20
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1.2 BOl'tDlJME THH::l<lNBSS

-SeU plerce rivets, ~ow,e!st cost ,I lock assembly 'QIG'Oml,e'try, access needed to both slides BUnd rivets~ location or tolerance aosorbuon ,sing lie slde access

-Extruslon interllocks

-AU hold assemblly in place afiter

remlovai from assemly jli'gl and du.ning adhesive cur~ngl

-A,II r,e,£dst peel In high deformation events

,2:9kg front end lin assambly fixtu ra .~ lbuiliit vertically for tool and fiixi n'g access

Fixturlng

-Ths fiixturiing desiign ls controlled biy the hardpoints on 'the structure, part lcadlnq, fix:lingl gunaoci9'sS and buUd volumes.

-Flxtures an;~ designed to be' lin series, with sub asselmbiies fee(Ung into a main assembly

• The flixtur~ng was als,Q de'signed for future modifications SOl a. longer or w~der chassts could be produced with ml nimal 'toolling changes

-Capaoity of 900'0 p.a,

Mla~n assembly f~xture

11 61kgTub in chassle ~nou re flixtu ra

Adlhesives -Ad'va,nlages

., No local stress raiisers

• No [m aterl all softening

• Diiss,imlil ar mate rials, can be joi ned ., Gap f II ii ngl capability

., Accuracy OIf fInished ass'B:mlbly ., No high resldual stress

., Slmplliifi.e,s the de:slgln process ., Lo,w 00:5,t

Lotuis Engiineering

Lotus Evora CAE Overviiew

St,8'lic Torslon and Belndiing - Tub Onlly - St:r'ailn Energy Dis'trilbutiiolnl

''''

- i_ M

~ :1~:t'!1I~'~1

_C'_'-.I'i_ .,:l , •• ~ ~~~1_1 r I

S~lllselotions optimised usi ngl A~tailr Opiistruct.

Dorrmated by bend il1g requilrem,eHt for converUblle.

Bend il1g 81kNlmmi

__ G'_f 11.11'''::

~ii ... ~":;~~ jl.1*:~'

~_I

l I

Software tools:

• !i!.I..Ir~ ....... irTllrl

lIiIIIIi.·tL.lli(iII'lil:illli~1

LS Dyna8dl and Oasvs (ARUP')

Nastran Hypermesh/Optlstruct MSC/lFatigue

Lot:us Englln€N3rlng

Tank bay celli and shear pane~ key structural ~tems for tub torslonal 5t~ffrness.

Slatic Torsion and Bendlnq- GB,IW+ Tub- Strailn Elnlsrgy Dlstrlbuflon

(31lazed 'GRP body and nibtorslon and , bending.,

Compostte body is structural u nUk;e EUse. Bonded to tubwiitih IBeta,ma:te 2g00s and

I ergs bondareas.

lUI D 9Ia.$:$, filbre inwindSloreensu rround (WSS), IRoofr~A Pililar andi Cant raU.WSS

and C,antralil toam cored.

B,e,ndling1 O",5Ik.IN/lmlm Torsion 2BlkNm/de'QI Totallw ht 2,851kg

OU)JlJ ..JUII--

~1";"'Vii~~lI:"~ r-..I~

\. ,.

L

Torsion and Bendingl MOldes - Trimmed GBIW ,+ TubSI:r,ainEnelrgy Diistribut:ion

~I_ Jl. ..

-,\H" .. I ..:ol~ Pseudo trimmed body model with

distribut,ed mass forearl-' lndlcatlon o.f

-- --- -- ---- -- -- y - - -----

·tri mimed body modal lbehav~our before dotal Is, rn ass, Ii nrormanon avaUabh3.

Use to driive optlm,is.at.iion for sm extrusion slz.ing.

Method supported by test/analysis (Jorr'9'lation on E Ili:s;e and IE.vora..

l!.Dl.~_ .JlloO:l..:l

-':.#.~J"~.L"'IL"1:iI !!!!.~!"I lullil.o»t!J

jIo-'irI!IIf

1st Bending Mode a1 ... 6Hz

t

~ ~I • I'

1 S~ Torsion Moo.e 35~ 11BHz

IRlv Bondling Dev'elopmenl _, Adhesive Strelngtlh FE Cor'rellat:ion

IE,arlly developlment tests, on fron~: end structure. SPR and bonded structure

FE mlOde'l with adhesiive and. rivet fa~llure

Good correlation of de,form,atiion behaviour and adhes,iv,e fainu re

Front lmpact 35mphl Ri'giidbar'rier

I !!!!!i~iI! ~ TrTii'lll' n 11!11~ ~""I'lil __ ~,~.,,,,

~ n 351m ph rii'9Ii,d barriier ~Imp,act both doors easl Iy openable post testwitl1 m~n~ma,lfoorwEdll de'fiormatlon. Major dalmage to front 5ubfrra.mlC3 onlly.

In 'O'DB barrier impact both doors easiily openalble post test, with miinimall fo'orwell~ de,formatlion. Majl,or damage to frontsuotrama only.

Very good side impact performance with lhilQlh sill I:! 5t.eel 8 pi Illarfirame and 7000 series extruded door beam,

INo deformation of rear bu~k head.

IMi nilma,1 engine movement, Doors, aasl Iy opened. Good energy absorpflon of rear subtrame.

IR'oof Orush - IH'ybridl Comp,osite and Steell Fri8lme

Shown in deformed state.

G,omposilte panels return to origilnall shape but with some local fractures.

,.

!!Ii'] ~-ifII ~J ...

_-I'niI

Steel Frame

GRP Composite Structure

1"'" ....

rI ... __ ~

-.

•. ~- ~I"

..,...-. rl-F" LI -"-" .....

-.

Pilots show contribution 'of shear pane'ls to wishbone mount V stiffness

Lotuis Engiineering

Lotus Evora Chassis System Assembly

Majo'f assem b[ledi litems::

Front subtrarne IHVAC unlt [Radiiator Ste,eringl rack, [Front suspension [Front brskes

Chas,sis Assembly - Front Module

Chas.sis, Assembly _, Ce'lnter Modulle,

'-"'.

Ma.jo,r assam bled iite

Tub

Slel9,ringl col umn IP,edalls,

'Gearshift

IFue11 syste1m

iFront to rear p~pes. Air distribution unit

_,

•

ChI8SS,is, ,A,s,semb,ly - C1enter Mo,dull,e

Major' assem b!led ltems:

Rear subtrame Powertrailn Exhaus,t

AIr ci'9'aner Hear .-,.- · •••.. nlt!i .. "ea suspe .. 80_ .

Rear brakes Water header

LEV2 Federal Compllam Sta~nl,e'ss Steel Tank with 601 itres Capacity.

Vehi,clle Assembly - Roilling 'Clhas,sis

Front Subframe J1oint- R,epailrabiiliity

• Pate,nted da,mage II imiitatlon syst,elm employed at frontsubtrarne joint

·M,ain structure (01 ue) remalns undamaqed when crash rall (gre,en) andsldepllate,

( .. -. re. '. have ' /ii9'llde,d

gy, . .., .

Major' assemb led i1iemls:

Ductwork,

Whe,ehj and tyre:s, Bootbox

Str1u1ctural Aerodynamic Underpanels

• StructurEd !a~u miniulm front u nds"rtray witlh ramp 'warnilng

• StructuraJ a~umlniiUlm rear undertray with NACA ducts

• AI umi niium rear diffuser

Lotuis Engiineering

Lotus Evora Body Assembly

Evora. body assembly, just two stafons requilred

Seat be'it anchorageframle and rear bulkhead assembled to lower structu re

Fi rst bodyassemb!y station .~. screen surrou ndl then body sides

~, .. ri!il

Lot:us Engll1nsrsring

Second lbody assemblystation - doors

Body panels Sotlra IATM ,Si:

SMC

BUlmpe,r ski,lns BRIM Wiindscreen 3pl~t .~. AG P

Lotuis Engiineering

l.otu S •• ·····•· E vo ra St n -I c •• · ·t- - - re· •••• ·.····• _IV S-~- -- lta bill ltv - .. u - - .. - . ... .. - u. u - .. _. .. u - .. _. - - -y

Exampl,e ofEV powertraln p'8cka'ging within standard Evora. track and wheel base

IBattery enelosure is a permanent part of the vehic~e structure, containinq a 71 kWh pack, air cooled as re'quired

itfSlt~h~~~~' ,2001kW motor linked to differenUal" :8 poi nt torque axis mounting, wat.er cooled

DClD'e converter

lnvertsr located aoovs motor

IBatte,rry pack,

., Largest. c:apa,c.ity ,sho,wn wlhich fits within unchanged Evora wh!sallba.se and track

• 192 1 OOAh Kokarn cells

.. Circa, ,230mill,F3 r,ange

• Assembled onto structural platforlm ., Loaded vertlicaUly from b,e,I,Qw

High level package

.' Two 99thO/oiha occupants

'.' ,257'5mlm whee.llbase as Evora .' !Front and rear track as Evora

IEvora IPllat:forlm Modifled for Aliternative Vehlcte Type

• Wii,dlened .~ for addiitiona~ occupanrt~lmotor and battery spac,e

.. Lengthened - sill Is extended for additionall rear occupant spao(3'

• Dash structure railsG!d- to su it h~gher drivlingl position

A.lternative EV IP,8ck,age

• COlnvent~onaJ seating positions

., !Batteries under seats

IEvors structure has:

., Stiffness

• Durabillity

• Light weight

'. Crashworthlness

• A.c cu racy

" Low investment

• Law pi ece cost

And

• IPaoka,ge effioliency

., RepairabUity

• Contemporary NVH

• Silze valliation capabUily

Lotuis Engiineering

Thanlk You

Copyriglht of Lotus Cars Ltd