Tubular Structure of an Urban Electric Vehicle with High Crashworthiness Performance

Abstract This work summarizes the methodology and results of the design of a light and safe vehicle structure based on high-strength steel, aiming at its introduction in urban environments. The structure is made of a tubular chassis design easily scalable and modular, taking into consideration safety features from the very beginning of the design stage. The structural integrity of the vehicle from a static point of view is validated through torsional and bending stiffness simulations and experiments, as well as fatigue assessment. The crashworthiness is evaluated by applying the procedures set in regulations R137, R95 and R94, with special emphasis on vehicle occupants’ protection and on other vulnerable road users, with the objective of achieving a 4-stars EuroNCAP rating.