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Universitas Indonesia has developed several electric vehicles, one of which is an electric bus. In order to fulfill the local content of this vehicle, reverse engineering of the R260 ladder frame type chassis is carried out. In this paper, to fulfill the local content, we used material of the ladder frame is type SS400 from PT. Krakatau Steel. Afte...
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University of Indonesia Electric Bus was first developed using Hino R260 chassis. For further development, especially to fill out local content, it must be carried out engineering of its components. One of which will be discussed in this paper is the spring component. Reverse Engineering method is used to redesign in such a way. Measurement of the...
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... The design process commences by surveying existing designs and conducting an in-depth review of pertinent literature. Subsequently, the chassis dimensions and material properties are established [20]. Given that the chassis constitutes the fundamental structural element of the vehicle, a comprehensive strength analysis becomes imperative [11,21]. ...
This paper focuses on the design and evaluation of hollow frame structures for the development of two-passenger electric vehicles targeted for urban use. The primary problem addressed is the lack of focused research on efficient, lightweight, and safe electric vehicle frame designs, particularly for urban transportation needs. Through 3D simulation and Finite Element Analysis (FEA), this paper successfully develops a hollow frame design with dimensions of 2,148×800×640 mm and a weight of 40.77 kg that meets strength and stiffness criteria. The analysis shows that the design has an adequate safety margin with a safety factor of 2.053e+01. ASTM A36 steel is chosen as the material, balancing strength, stiffness, and cost. The results offer an innovative and practical solution to urban transportation issues, with broad potential applications in the electric vehicle industry. In particular, this study focuses on the specialized needs of urban-centric, two-passenger electric vehicles. The Finite Element Analysis (FEA) used here serves as a robust validation method, effectively reducing the need for extensive physical testing. This accelerates the R&D process and opens possibilities for future studies on alternative materials and dynamic loading conditions. The study's limitations and future research directions are also discussed. Moreover, the study's computational methods offer an eco-friendly alternative to traditional physical prototypes. This aligns with sustainability goals and provides methodologies for future studies. With rising urban populations, the demand for efficient vehicles is increasing. This study paves the way for city-focused, two-passenger electric cars that meet modern urban needs and sustainability goals
... This is why research related to vehicle weight is also being carried out, especially in relation to the design of the body and chassis. A lighter chassis and body and a greater strength will be of tremendous benefit [15]. Furthermore, this will affect the determination of the battery capacity. ...
This study aimed to determine and analyze the performance of an electric motor installed in a small city car, which was an internal combustion engine (ICE) car with manual transmission and front-wheel drive converted into an electric vehicle. A manual transmission vehicle was used, considering its type is the cheapest. This was to push aside the perception that electric cars are not accessible to the lower classes. Another technical matter was the focus on the power and torque performance of the electric motor and the transmission. A 7.5 KW three-phase induction motor was installed and assembled with 200 AH 76.8 VDC batteries. Electronic power steering (EPS) and the air conditioner (AC) were not operated, while power for the electrical accessories and power analyzer was obtained from a separate 12 VDC battery. Vehicle analysis focused on the power consumption, which was measured and acquired using a power analyzer. The vehicle was driven in real terms with three passengers. GPS was also used to determine the vehicle position and collect elevation data during testing. The derivatives of the GPS data were the speed, acceleration, and distance traveled by the vehicle. The initial hypothesis was that the car could cover a distance of 30 km with regular usage.
... These electric cars are innovations by FTUI lecturers and students who are members of the UI Molina Team. This research is about primary car electric design [1] at the University of Indonesia, energy optimization [2], chassis design [3], brakes [4] [5], transmission [6] and steering systems [7] [8]. The EV bus is a vehicle with a capacity of 60 passengers with motor power of 120 kW and 300 Ah. ...
... The components of the steering system are wheel drive, column steering, lower column steering, drop link, drag link, drop ext link, ext drag link, knuckle, spindle assy, end tie rod, long tie rod. 2. The main dimensions are 45 mm drag link rod and 50 mm ext drag link. 3. Static load that works on drag link is 17,843 N and on drag link ext is 22,615 N. 4. The material used for these two rods is the production of Krakatau Steel, namely S45C JIS G 4051. 5. Von misses stress that occurs in these two rods are 11,225 MPa and 190,7 MPa, respectively. ...
Universitas Indonesia has developed several types of electric vehicles as conversions from conventional vehicles. Among these types of vehicles that have succeeded are city car and bus types. Electric buses currently use the ladder frame chassis system. In this chassis system there is a hydraulic steering system. In order to develop a hydraulic steering system into an electric steering system, it is necessary to study the existing mechanism of the steering system. Static analysis is a form of study of this mechanism to determine how much the forces acting on each link. The steering mechanism system on this bus has a different shape from a vehicle such as a city car. The differences include the distance from the steering wheel to the front axle is relatively far. Due to this long distance, there are many links that build this mechanism. Static force on the front wheels of 6 tons will continue to the steering wheel. Deciphering the forces between links needs to be done so that you can definitely work with each link's force. After the force of each link is obtained, the stress acting on each bar will be used for the selection of the appropriate material. The use of local materials will be simulated through CAD software to obtain the smallest safety factor produced. Shape and size simulations will be carried out in this analysis to obtain optimum results for each link in this steering mechanism. Transfer of force from the wheel to the steering rod through a six-link mechanism. The material used is S45C JIS G 4051 equivalent to local content material KS 1045. The maximum stress that occurs at the drop link extension is 190.72 MPa and at the drop link is 569 MPa.
... The mode shapes are from 1 to 5, with the lowest frequency of 11.798 Hz, 21.009 Hz, 23.876 Hz, 30.84 Hz, and 36.463 Hz [18]. The results of static analysis in addition to producing a shape mode, as has been published, are also used to see stress, deflection and safety factors. ...
This research aims to simulate structural steel 400 (SS400) material as an alternative material for the electric bus's chassis structure. The kind of the material is low carbon steel. The SS400 material is produced from one of the largest steel mills in Indonesia, considered a local material. The local material used to increase the total domestic content in electric cars in Indonesia could be improved. Generally, the reverse engineering method of the R260 ladder frame type chassis is used to increase the local content in electric vehicles. However, this research used a ladder frame of type SS400 from local material to fulfill the local content of vehicle (EV)-bus chassis with the reverse engineering method. After the model was successfully created using the finite element software, statics analysis was carried out using the von Mises stress and the simulation results' deflection. The meshing process of the chassis structure is carried out in such a way as to assume global contact. Loading was evenly carried out over the two main beam ladder frames totaling 14,200 kg. The elasticity modulus and tensile strength values used for the material are 190 GPa and 480 MPa. Furthermore, the support was placed in the mounting position of the front and rear wheel leaf springs at a front, rear overhang, and wheelbase distance of 2,380 mm, 3,290 mm, and 6,000 mm. The resulting approach was carried out using a beam model with a two-overhang beam model. The simulation results showed that type SS400 from the local material obtained a maximum von Mises stress value of 75.8 MPa, deflection of 2.568 mm, and the lowest safety factor of 3.2. Meanwhile, through theoretical calculations, the obtained stress occurred in 72.33 MPa and deflection of 2.594. There is no significant difference between simulation results and theoretical results
University of Indonesia Electric Bus was first developed using Hino R260 chassis. For further development, especially to fill out local content, it must be carried out engineering of its components. One of which will be discussed in this paper is the spring component. Reverse Engineering method is used to redesign in such a way. Measurement of the existing leaf springs in the chassis is done. The dimensions and number of leaf springs for the front and rear wheels of the chassis are produced. With CAD software and finite element analysis, a static analysis is performed on each of these springs. Front axle leaf spring arrangement consists of 8 spring sheets with dimensions of width 80 mm and thickness of 10 mm with stratified length. Rear axle leaf spring arrangement consists of 5 spring springs with dimensions of 90 mm width and 12 mm thickness with evenly distributed length. The theoretical stress on the front leaf springs is 512.74 MPa and finite element analysis is 531.5 MPa. The theoretical stress behind the leaf spring which occurs is 721.67 MPa and elemental analysis up to 728.4 MPa. The material for both of these springs is chosen is 65 si7 or SUP9.
