Aluminium Intensive Vehicle Enclosures (ALIVE)

创新的高强度铝合金、新颖的加工、连接和组装技术已被开发用于轻质耐碰撞电池外壳，并将此类结构集成到超低排放车辆（ulev）中。挤压和薄板的最佳组合可以提供建筑灵活性，以满足保护结构和热管理要求，可以将电池工作温度控制到精确的水平，降低热失控的风险，并在充电和驾驶过程中优化电池组工作温度，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，利用灵活的多平台单元在相同的生产设备上，设计以满足可变体积需求，同时为本地组装和出口选项提供一套零件。这使得作为OEM技术示范的多个电动汽车平台得以引入，对于支持OEM加速实现大批量电气化计划至关重要。如果没有这样的解决方案，当前生产方法的高资本和制造成本将成为小批量、中批量和大批量生产的重大障碍，从而推迟电气化时间表。提出的解决方案通过将资本成本降至最低，提供大规模生产的规模，进一步降低了供应链的风险。这在制造和组装成本以及设置时间方面具有显著优势，同时满足当前的立法要求，为制定新的安全、碰撞管理和能源效率标准提供了机会。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，通过提供符合当前和未来电池模块技术和功率密度的轻质外壳，形成一条通往英国电池组生产的综合途径。该项目旨在通过颠覆性的高强度铝合金及其加工和连接技术迈出重要的一步，为英国市场的新一代轻型混合动力和电动汽车的汽车集成结构和电池外壳的制造提供新的外壳设计概念，这将对英国政府的碳减排目标产生重大影响。该项目将建立一个位于英国的制造工厂，生产世界领先的经济高效的结构铝电池外壳，为纯电动汽车和插电式混合动力汽车组件制造提供陆上资源，其制造概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.