University of Twente Student Theses


Developing of a new subframe for TheWheel

Hendriks, M. (2018) Developing of a new subframe for TheWheel.

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Abstract:During this internship I worked on two main assignments at e-Traction, Apeldoorn. e-Traction builds and develops electric in-wheel motors called TheWheel. The current TheWheel V0 will be replaced by a new generation. This new motor is more powerful and will be more efficient. As the design of this motor is different a new subframe needs to be developed. The connection to the subframe will be closer to the middle leaving less space available for the subframe. The first main assignment was to develop a new subframe for the testbus, a Volvo 7700. The goal of this subframe is to test the new motor on the road. It must connect the suspension arms, reaction rods, stator shaft and brake caliper. As there is limited time available for this subframe there is chosen for a quick design approach, which made it very challenging. Mostly there will be looked at proven thicknesses and threat depths of previous designs. Where high stresses are expected overdimension of parts will be used. There is chosen to convert a V0 VDL subframe in stock to fit with the new motor as this would be more beneficial. From the final testbus subframe design a FEA was done from which no high stresses in the subframe are expected. After that the technical drawings and an assembly guideline of the subframe and the new motor were made. The parts arrived and the subframe was being built in-house during the last weeks of my internship. The second main assignment was to design concepts for a production subframe. To do so there was looked at the geometric boundaries, load cases and service demands. After that 3 conceptual designs were made. The first concept is based on the current V0.3 ZA subframe. This subframe is proven to be reliable and strong over its life time but has relative high production costs. Therefore the second concept is optimised for production efficient parts. This means where possible straight plates and symmetric parts are preferred. This leads to a cheaper and lightweight subframe. The third concept will use a casting part. With the use of a casting part less parts are needed as previous used parts are integrated. Due to its shape it is heavier than the other concepts. FEA were done for a comparison between the concepts. From these FEA the casting parts show room for improvements and less stress compared to the other concepts. After evaluating all concepts the third concept with the use of a casting part shows the most potential and need to be further investigated.
Item Type:Internship Report (Master)
Faculty:ET: Engineering Technology
Programme:Mechanical Engineering MSc (60439)
Keywords:Subframe, Bus, Concept, Design, FEA, Assembly, Montage
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