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Numerical analysis of the strength and stiffness of triggo light electric vehicle body

Stachowicz Łukasz, Boczkowska Anna, Budweil Rafał

Composites Theory and Practice

2025

R. 25, nr 1

38--48

TRIGGO is one of the first vehicles to effectively combine the manoeuvrability and parking advantages of twowheelers with the safety and comfort features comparable to those of small passenger cars. It is intended for use in a short-term rental network and should be characterised by low energy consumption. To this end, it is reasonable to optimise the vehicle's design towards minimising weight. The use of composites in the TRIGGO body structure enabled a reduction in the ready-to-drive vehicle weight and optimal utilisation of the available space. This choice makes it possible to keep the body weight low while ensuring appropriate mechanical properties. The subject of this paper is numerical analyses of the strength and stiffness of the TRIGGO light vehicle body made of glass-epoxy composites. The scope of the work includes the construction of a computational model of the TRIGGO vehicle body made by the RTM method with a double skin and foam core, in addition to calculations of the stiffness and strength of the structure during body load tests. For this purpose, an FEM computational model was built based on the 3D body model. The body of the RTM version of the TRIGGO vehicle consists of 27 separate components, which are connected to each other by rigid bonded contacts. The composite structures with foam cores were modelled as single-layer shell elements including all the layers of the composite, and a foam spacer. Three design cases were developed: P1.1 - vertical-transverse body loading, P1.2 - vertical-longitudinal body loading, P1.3 - vertical-longitudinal body loading with a horizontal force component. The calculation cases were determined based on "Regulation (EU) No 168/2013 of the European Parliament and of the Council with regard to requirements for the functional safety of vehicles for the approval of two- or three-wheel vehicles and quadricycles", in particular Annex XI of this document. The calculations prove that the glass-epoxy body of the TRIGGO light vehicle meets the requirements for strength and stiffness.

Development of a method for producing composite parts of the TRIGGO electric car based on A.S.SET epoxy resin powder - feasibility study

Boczkowska Anna, Stachowicz Łukasz, Budweil Rafał

Composites Theory and Practice

2024

R. 24, nr 4

246--252

Composite materials due to their outstanding mechanical properties and light weight are becoming increasingly im portant in the automotive industry, helping to develop lighter, more durable and environmentally friendly vehicles. It is espe cially important in the context of electric cars such as TRIGGO. It is an innovative electric vehicle (EV) designed with a focus on urban mobility. One of the unique features of this car is its compact design, aimed at providing a flexible solution for city driving. In this paper a method for manufacturing composite components of the TRIGGO electric car body by pressing tech nology, based on the innovative A.S.SET resin is described. It was confirmed experimentally that selected components of the TRIGGO vehicle body are feasible to be fabricated by pressing technologies using SemiNEMpreg pre-impregnated material based on A.S.SET epoxy resin. The studied technologies cover thermoset sheet forming using a membrane press or a hydrau lic press, also using a vacuum-assisted oven. These technologies were adapted to the requirements of manufacturing composite parts, with a special focus on the cost-effectiveness of the process. Owing to the use of the fast-crosslinking snap-cure epoxy resin with the trade name NEMresin (known as A.S.SET), it was possible to shorten the crosslinking process to 15 minutes. The studies made it possible to select the type of mold depending on the geometry of the component and the applied technolo gy. The studies led to the determination and matching of the type of component to the type of mold and predestined manufac turing technology, taking into account the most important factors affecting the start of mass production, such as the number of pieces, the surface quality of the component, i.e. roughness coefficient and surface finishing, mold cost, process time, pro cess cost, required repeatability, quality of the target component structure, as well as the cost of finishing. The developed technologies are innovative and allow the low-cost batch manufacture of composite parts for the automotive industry.