Development of a lightweight passenger cell for a highly efficient competition prototype vehicle

In the development of Battery Electric Vehicles, the efficiency is one of the most important parameters to be optimized to reach the project targets in terms of range and vehicle performances. TUfast Eco team is involved in the design of high efficiency vehicles to participate in the Shell Eco-marathon competition. The new vehicle is called MUC022 and will take part in the 2022 season. The aim of this work is the design, in CAD environment, of the outer body shape of the car and the relative structural part, a monocoque in Carbon Fibre Reinforced Plastic material. To increase the efficiency, the weight must be reduced while the aerodynamic performances improved. The result is an optimization of the body shape and a reduction of the vehicle projected frontal area. These outcomes are feasible thanks to a streamlined style optimized by means of CFD analysis. The concept must comply with the competition regulations, respecting the stated vehicle external and internal dimensions while assuring accessibility and roominess for the driver and his/her luggage. The monocoque model is derived starting from the outer body shape and refined in order to assure enough space for the various systems and subsystems of the vehicle. Furthermore, the structural integrity must be considered during the passenger cell design. A FEM analysis allows to assess and validate the strength and stiffness performances of the structure. The production requirements are also studied and implemented to assure the manufacturability of the described solutions. A reliable production process is selected, and the geometry properly adapted to the manufacturing procedures. The moulds of the monocoque are finally designed.