California Car Sensing Δ 13th of January 2014 Ω 5:11 AM

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~ sense for Ξ ~ Quantum Technologies ~ Fisker Karma Hybrid Testing in Southern California	~ YouTube ~ sense for Ξ ~ Tesla Motors	~ sense for Ξ ~ sense for Ξ ~ sense for Ξ
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«Car Sensing of U.S.	Θ	Θ
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~ Quantum Technologies

»Quantum Technologies

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~ Fisker Karma Hybrid Testing in Southern California

»Fisker Karma Hybrid Testing in Southern California
ξ see photos

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~ YouTube

»YouTube
ξ Google investor behind !!!
ξ military version with fuel cells before this model
ξ three hours in 220V to charge
ξ 6-10 hours with 110v in USA
ξ Astom Martin , BMW Designer
ξ GM behind Power Technoligies
ξ solar panels on roof
ξ Los Angeles pavement hot; keeps car and batteries cool
ξ military experience behinf this
ξ gas price helps

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~ Tesla Motors

»Tesla Motors

Cut From A Different Cloth by Barrie Dickinson, Director of Body Engineering

What’s so special about carbon fiber?
ξ the advantage carbon fiber has is that it’s very strong for its weight
ξ could use carbon fiber to achieve the same level of strength with less mass
ξ depending on how it’s processed,
ξ a carbon fiber-reinforced plastic part can replace an equivalent steel part using less than 30 percent of the original part’s mass

Carbon fiber on its own isn’t much use, though
ξ it’s like a very thin fishing line,
ξ it is only strong in tension (when you try to break it by pulling it along its length)

To make a panel that is strong in all directions
ξ carbon fiber is typically woven into cloth (to give it strength in two directions) and
ξ then the carbon fiber cloth is encapsulated in plastic
ξ in Tesla it is encapsulated in epoxy resin – it has a higher specific strength than the alternatives
ξ the epoxy is strong in compression but relatively weak in tension,
ξ so the two materials act together to produce a panel strong in tension and compression

Carbon fiber parts that you see on some cars, especially aftermarket products
ξ are produced using carbon fiber cloth pre-impregnated with resin (abbreviated to ‘prepreg’)
ξ that is heated and pressed against a former in a pressurized oven called an autoclave
ξ the very high temperature and pressure squeeze the air out of the cloth and
ξ force the resin to flow around the fiber and create a consolidated molded panel
ξ this can produce very lightweight and very stiff components, but with a couple of drawbacks

Drawbacks in conventional solutions
ξ the cost of producing the parts is very high
ξ because they need a long time to fully cure in the autoclave and
ξ the process isn’t cheap
ξ there aren’t many manufacturers with enough autoclave space to produce a whole set of body panels at the rate we need

Tesla's Resin Transfer Molding (RTM)
ξ called a “closed mold”
ξ two huge blocks of steel are machined and polished
ξ so that when they’re nested together there’s a gap between them of less than 2mm representing the shape of the part they want
ξ they lay carbon fiber mat and some additional material against the concave surface of the tool,
ξ bring the other half of the tool into place to create the cavity, and then inject resin to fill the gap
ξ this technique allows to control thickness (which keeps weight down),
ξ reduce processing time, and maintain a very good level of surface quality
ξ an additional advantage of using a closed-mold tool is
ξ that they can vary the thickness of the part in key areas to integrate features
ξ that add strength or provide a location for mounting hinges, etc.

For body panels
ξ high strength is needed in bending
ξ which is really creating tension on one surface of the part and compression on the other
ξ so that they can make thin, lightweight parts
ξ that can withstand the loads seen during a car’s lifetime (car washes, car parking lot contact, aerodynamic loads, etc.)
ξ to achieve high specific bending stiffness, they needed to get the carbon as close to the surface as possible
ξ panels are actually a sandwich made from two layers of carbon separated by a middle layer of glass and polypropylene
ξ that presses the carbon against the face of the tool and keeps it close to the surface of the panel
ξ to create a smooth surface ready to paint they spray the inside of the tool with a special paint primer
ξ that then adheres to the resin and comes out of the tool on the part

Tesla's carbon fiber body panels
ξ are made from a layer of primer, a layer of carbon, a layer of glass, a layer of polypropylene,
ξ another layer of glass and another layer of carbon,
ξ all encapsulated in epoxy resin and all in a space about as thick as a couple of credit cards
ξ this allowed to maintain a bending stiffness similar to that of a regular steel body panel and
ξ lose about 50 pounds from the weight of the body panels compared to ‘lightweight’ glass fiber composites

To get there
ξ the Tesla Motors body engineering team based in the UK and Barrie Dickinson
ξ spent two years working hard with the styling studio at Lotus,
ξ aerodynamic experts from the UK’s Motor Industry Research Association (MIRA),
ξ Tesla's body system supplier, and
ξ the manufacturing engineering team at Tesla Motors
ξ to arrive at a solution that satisfies all of our requirements

A global supplies of the particular carbon fiber cloth chosen dried up due to demand from
ξ aerospace: the new Airbus and Boeing superjumbo planes both make extensive use of carbon fiber
ξ defense manufacturers

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