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OPerating Energy Rack for Full Electric Vehicle





OPERA4FEV Project aims to manufacture electrical vehicle cheaper and lighter by using thermoplastic solutions for battery racks.


In July 2010, the consortium initiated the process to fund a large-scale collaborative project focused on the development of a thermoplastic rack with batteries for electric vehicles.

The Seventh Framework Programme (FP7) is the European Union's chief instrument for funding research with a total budget for FP7 is €51 billion over 7 years. From this amount, 25 millions were dedicated in 2011 by the Green Cars Initiative to finance advanced eco-design and manufacturing processes for batteries racks. The consortium applied to this programme and has been selected. In this European joint call, 4 projects among 11 were awarded.

This project, of which MECAPLAST SAM is the leader, has been submitted to the European Commission in December 2010 within the FP7 call under the name OPERA4FEV acronym of OPerating Energy RAck For Full Electric Vehicle.


This project involves a consortium of 10 partners from 6 european countries and has a total budget of €7 millions. The project started in September 2011 for a total period of 42 months.

Last minute !

The next meeting will take place in Issy-Les-Moulineaux on 28th of february
The kick-off meeting hapenned on 7th of september
The official starting date has been fixed on 1rst of september 2011

The OPERA4FEV project aims to develop thermoplastic battery racks on two functional demonstrators: one for a large scale vehicle from FIAT and one for a “niche” car, the F-City from FAM .To improve deployment of electrical vehicles in Europe, large scale production processes for Rack and electrical components need to be developed.


The innovative solutions proposed by OPERA4FEV will integrate electrical, hydraulic connections and component housing in a thermoplastic approach to reduce cost, weight and assembly time.

In order to show the relevance of the solution and meet strong industrial benefits, the two thermoplastics racks will be manufactured and assembled with industrial means.


The whole value chain will be addressed, including the eco-design (dismantling and recycling of critical materials), assembly and integration of cells and electrical components.

As safety of the on-board battery in electric, hybrid, and plug-in vehicles is of paramount importance to the international automakers, OPERA4FEV will pay particular attention to evaluate the effects of the rack characteristics regarding vehicle crash safety, and will focus on the potential risks for the vehicle and its occupants in case of failure of one or more batteries.



To sum up, the main issues relative to OPERA4FEV project are :

  • the integration of cells into the thermoplastic rack
  • an easier mounting and fast connexions of cells
  • the reduction of assembly time
  • 25% cost reduction on components (cells excluded) compared to existing rack
  • the improvement of dismantling for better maintenance
  • 50% reduction of number of components
  • the eco-design of the racks and easier end of life (materials, dismantling) based on life cycle assessment
  • the plastics parts design to improve thermal regulation, guaranty safety/crash behaviour and deal with large dimensions
  • the use of recycled polymers (70% in weight)
  • 30% weight reduction on components (cells excluded)
  • a concept proposal adaptable to automotive industry and evaluated with an representative tools and assembly line (able to reach 20 vehicle/day).

OPERA4FEV is labelled and supported by Plastipolis and Pôle Véhicule du futur French clusters.

Partners

MECAPLAST SAM

Monaco

 

MECAPLAST SAM is the coordinator. Mecaplast is one of the European leaders in automotive equipment for plastic parts. Founded in 1955, the Group designs and manufactures parts and complete systems for vehicle body and engine. It reports a turnover of 643M€ and has 5500 employees based in 14 countries.

CENTRE TECHNIQUE DE LYON - CETHIL

France

 

CETHIL is a research laboratory in thermal science and energy engineering. It is a research unit of INSA-Lyon, of Claude Bernard University and of CNRS. The staff of CETHIL are about 100 persons including 50% of professors, research scientists, technicians and administrative personnel, and 50% of visiting scientists and phd students.

CENTRO RICERCHE FIAT S.C.p.A

Italy

 

CENTRO RICERCHE FIAT, established in 1978, is an internationally recognized centre of excellence. CRF’s work constitutes a strategic lever for the FIAT Group’s businesses, enhancing performance through the development and transfer of innovative content which makes the Group’s products both competitive and distinctive.

EVE SYSTEM

France

 

EVE System is an engineering company, expert in design, prototyping and industrialization of electric architectures for electric and hybrid vehicles. EVE system’s root know how deals with cells integration and management for automotive application, electric hybrid vehicles supervision.

FAM AUTOMOBILES

France

 

FAM AUTOMOBILES is a company specialized in the construction and conversion of electric vehicles. FAM has design, engineering and industrialisation activities, prototyping and vehicle assembly line for car makers and FAM own project like the F-City car.

UNIVERSIDAD POLITÉCNICA DE MADRID - Instituto Universitario de Investigación del Automóvil

Spain

 

UNIVERSIDAD POLITÉCNICA DE MADRID is the oldest and largest Spanish technical university. The INSIA laboratory activities are related to the traffic accidents and vehicles safety, automobile industry, transportation sector and more recently to the transportation environmental impact.

OLESA - Indústria de Moldes, SA

Portugal

 

OLESA is an engineering and tooling company with consolidated competencies in the engineering and manufacturing of tools and moulds for thermoplastic injection. Olesa is currently supplying integrated tooling solutions for clients in the automotive, electronics, motorcycle and lighting industries.

GRUPO REPOL

Spain

 

GRUPO REPOL was founded in 1975 and is one of Spain's leading providers and custom compounders of Engineering Plastics (PA, PP, PC, PC/ABS, PBT, ABS, POM and PPS) for injection moulding and extrusion. Repol develops customized solutions to meet specific client needs, ensured by processes and state-of-the-art laboratory tests that fully comply with international quality and environmental standards.

MECACORP - CTM

France

 

MECACORP is the French subsidiary of MECAPLAST. Based in Lens, the Engine Technical Center (CTM) will provide expertise in the development, design and validation of electrical architecture and cooling system parts.

VRIJE UNIVERSITEIT BRUSSEL - ETEC

Belgium

 

VRIJE UNIVERSITEIT BRUSSEL has an internationally recognised, 35-year long tradition of R&D on electric, hybrid and fuel cell vehicles making it the premier electric vehicle research facility in Belgium. About 40 researchers are active in the MOBI Team, the mobility research group at the VUB. MOBI focuses its research on different fields related to sustainable transport and mobility, socio-economic aspects, environmental impact assessment and vehicle technology.

201228 Feb.

Consortium Meeting - Issy-Les Moulineaux

201114 Sept.

Kick-off meeting of the WP1 - Etupes

201107 Sept.

Project Kick-off meeting CRITT Bruay

201101 Sept.

Official start of the project

The project partners websites

Institutional websites

Clusters

For more information please contact the Project Coordination Team :

Mr Erwan LE FLOCH

Dr Bruno NABETH

MECAPLAST Group