FKFS Veranstaltungen

2025 Stuttgart International Symposium
on Automotive and Engine Technology

3. - 4. Juli 2025

Session: Vehicle Technology I | | 17:35 - 18:05

Advanced Composite Technologies for Next Generation BEV - EMC,Crash, Cooling

Bernhardt Lüddecke, KAUTEX TEXTRON GMBH & CO. KG

While metallic structures in BEV are state of the art for the white body and the battery system, composite and plastic structures are an emerging technology. To fully exploit thier potential, they need to be seen as a design-element, rather than just a replacement for a given metallic design space. As composite prototype are more cost intense due to required mold and fixture investments, the importance of virtual design and development is even more pronounced. Hence, in a series development project, one generation of sampling (A-samples) will entirely be avoided, but serious concept decisions have to be taken. In addition, there is a lack of experience, as especially plastic battery enclosures are introduced for the first time into the market. They require and include new solutions e.g. for EMC protection, crash safety, and cooling. Consequently, silos in between experiment & CAE are totally unacceptable. Every piece of data needs to be streamlined and fed into the development cycle. Planning, scheduling of both tests & CAE have to go hand in hand. Data require to be stored with reference to each other and handled as a whole. Data mining and access to relevant meta data need to be re-assessed and re-shaped. Kautex designed and developed 3 Demo Vehicles to prove in-situ performance of its products and the development approach. Convincing results and comparisons of composite vs. metal (both simulation & experiment) regarding EMC, Crash and Thermal Management are presented.