The proliferation of the electric vehicle (EVs) in the US market led to an
increase in the average vehicle weight due to the assembly of the larger
high-voltage (HV) batteries. To comply with this weight increase and to meet
stringent US regulations and Consumer Ratings requirements, Vehicle front-end
rigidity (stiffness) has increased substantially. This increased stiffness in
the larger vehicles (Large EV pickups/SUVs) may have a significant impact during
collision with smaller vehicles. To address this issue, it is necessary to
consider adopting a vehicle compatibility test like Euro NCAP MPDB (European New
Car Assessment Program Moving Progressive Deformable Barrier) for the North
American market as well. This study examines the influence of mass across
vehicle classes and compares the structural variations for each impact class.
The Euro NCAP MPDB (European New Car Assessment Program Moving Progressive
Deformable Barrier) protocol referenced for this analysis. Our evaluation
approach comprises of two sections: (i) The impact of the barrier mass on to the
vehicle structure (V2B) and (ii) vehicle-to-vehicle impact (V2V) analysis. To
predict the correct segment weight representing the barrier weight for the North
American market, we analyzed the 2022 year to sales data for North American
market to assess the average vehicle weight. Data was then compared with CAE
predictions barrier mass (~1500kg- 1600kg). Based on the sales data, the average
vehicle mass found to be ~1500 kg, aligning with the CAE simulations
predictions. This study aims to determine the US sales volume and conduct CAE
simulations to predict the precise weight of the barrier that replicates the
lightest vehicle currently available in the North American market, as per this
study, a barrier weight of (~1500 -1600) kg can be considered for the future
vehicle compatibility for NA market. This predicted vehicle weight aligns with
the typical vehicle sale data for North American market.
Background
In 2022, Electric Vehicles (EVs) constituted 14% of all car sales globally,
with every major market experiencing year-over-year sales increase. In
United States, this meant that over one in five cars sold were electric. To
improve the range of EVs, Original Equipment Manufacturers (OEMs) are
significantly increasing the weight of high-voltage battery assemblies,
leading to an overall increase in the vehicle weight, this in turn, results
in substantial increase in front-end-stiffness of the vehicle to meet other
US vehicle regulations. The heightened front-end-stiffness is expected to
significantly impact vehicle compatibility. To understand various parameters
such as Occupant Loading Criterion (OLC) and Standard Deviation (deformation
of barrier profile), we referenced Euro NCAP MPDB (European New Car
Assessment Program Moving Progressive Deformable Barrier) test protocol.
This helped determine the weight of the barrier that represents the small
vehicle segment in the North American market. Vehicle-to-Vehicle (V2V)
impact CAE simulations were also conducted, selecting smaller vehicle as
target vehicles (to represent the barrier mass), and impacting them with
different vehicle classes such as Pick-up trucks, Large SUVs, and Compact
SUVs. The impact vehicle mass varied from 1800kg to 3200kg.The primary aim
of this study is to estimate the barrier weight that replicates the lightest
vehicle currently available in the North American market.