Aluminium Intensive Vehicle Enclosures (ALIVE)

创新的高强度铝合金、新的加工、连接和组装技术已被开发用于轻型防撞电池外壳，并将此类结构集成到超低排放汽车(ULEV)中。挤压件和板材的最佳组合可以在满足保护结构和热管理要求方面提供架构灵活性，可以将电池工作温度控制到精确水平，降低热失控风险，并优化充电和驾驶过程中的电池组工作温度，以减少能量损失。新颖的外壳架构将提供可扩展的设计和制造概念，利用相同生产设备上的灵活多平台单元，满足不同的批量需求，同时为本地组装和出口选项提供部件套件。这使得多个电动汽车平台能够作为OEM技术示范者引入，这对于支持OEM加速到大容量电气化计划至关重要。如果没有这样的解决方案，目前生产方法的高资本和制造成本成为低、中、大批量生产的重大障碍，从而推迟了电气化时间表。拟议的解决方案通过将资本成本保持在最低水平，提供扩大到大批量生产的规模，从而进一步降低供应链风险。这在制造和组装成本和安装时间方面提供了显著的优势，同时满足了当前的立法要求，提供了定义新的安全、碰撞管理和能源效率标准的机会。Alive项目将为宝马和沃尔沃电动汽车设计、开发、组装和广泛测试铝密集型原型外壳和全尺寸演示外壳，通过提供与当前和未来电池模块技术和功率密度相匹配的轻型外壳，形成一条通向英国电池组生产的综合途径。该项目的目标是在颠覆性高强度铝合金及其加工和连接技术方面迈出又一重大步骤。为英国市场制造新一代轻型混合动力和电动汽车的车辆集成结构和电池外壳提供新的外壳设计概念，这将对英国政府为英国车队制定的碳减排目标产生重大影响。该项目将在英国建立一个世界领先的高性价比结构铝电池外壳制造工厂，为BEV和PHEV零部件制造提供陆上资源，其制造理念能够为出口组装提供高效的零部件运输。

Innovative high strength aluminium alloys, novel processing, joining and assembly technologies have been developed for use in light weight crash resistant battery enclosures and for the integration of such structures into ultra-low emission vehicles (ULEVs). The optimum combination of extrusions and sheet can provide architectural flexibility in meeting both the protective structures and the thermal management requirements which can control battery operating temperatures to precise levels reducing, the risk of thermal runaway and optimising battery pack operating temperatures during charging and driving to reduce energy losses.The novel enclosure architectures will provide scalable design and manufacturing concepts utilising agile multi-platform cells on the same production equipment, engineered to meet variable volume demands, while providing a kit of parts for local assembly and export options.This enables the introduction of multiple EV platforms as OEM technology demonstrators, critical to supporting OEM acceleration to high-volume electrification programs. Without such a solution, the high capital and manufacturing costs of the current production methods act as a significant barrier to low, then medium and high-volume production, thereby delaying the electrification timetable. The proposed solution further de-risks the supply chain by providing scale-up to high volume production by keeping capital costs to a minimum. This provides significant advantages in manufacturing and assembly costs and set up time whilst meeting current legislative requirements, providing the opportunity to define new standards of safety, crash management and energy efficiency.The ALIVE project will design, develop, assemble and extensively test aluminium intensive prototype enclosures and full-scale demonstrator enclosures for BMW and Volvo electric vehicles, forming an integrated pathway to UK battery pack production by providing the light weight enclosures aligned to current and future battery module technologies and power densities.The project aims to take another major step with disruptive high strength aluminium alloys and their processing and joining technologies, enabling new enclosure design concepts for the manufacture of both vehicle integration structures and battery enclosures for a new generation of lightweight hybrid and electric vehicles for the UK market that will have a major impact on the UK government's carbon reduction targets for the UK vehicle fleet. The project will establish a UK based manufacturing facility for world leading cost-efficient structural aluminium battery enclosures providing an on-shore resource for BEV and PHEV component manufacture, with the manufacturing concept capable of providing efficient transportation of parts for export assembly.