Collaborative automotive engineering project anticipates industry change ~Together with FaroArm~

In the development stage, the team aimed to optimize the structure of the car, gunning for a lightweight body and a decrease in rare metal use. OVEC-ONE showcases a variety of efforts from participating companies. For starters, in developing a versatile in-wheel drive motor, the team set two design conditions for itself: the motor had to fit in a 16” wheel and it had to be compatible with strut-type suspension. The team managed to satisfy both conditions, making OVEC-ONE the first EV with this achievement. In addition, the drive motor does not contain dysprosium, a rare earth element commonly used in hybrid vehicles. This meant that the team also managed to reduce the usage of rare metals.

Introduction
Mitsubishi Motors Corporation, world leader in mass production of electric vehicles (EV), has one of its production bases in Okayama, Japan – a place where many other automobile-related companies choose to locate. In response to the changing environment around the automobile industry, Okayama Vehicle Engineering Center for the next EV (OVEC) was founded in 2011. OVEC was built with the next EV in mind, and equipped with the latest production systems that the industry endorsed. In addition, OVEC led the Okayama Vehicle Engineering Project for the next EV, a network that is based on three main pillars – Manufacturing Technology, Human Resource Development, and Network Enhancement. A total of 16 companies in the prefecture are part of this network, which strives towards the common goal of building an automotive industry cluster that is internationally competitive and ready for the “Next Generation Vehicle”.

Dr. Tomonori Katsuta, Chief Engineer of OVEC (operated by Okayama Prefecture Industrial Promotion Foundation), said, “Most of the 16 participating companies are automobile component related manufacturers, but some are from other industries such as materials, facilities, and shipbuilding. As the production of EVs grows, a drastic shift is expected in the proportion of machine components and electrical components required. Our early involvement in the development of next generation vehicles, beginning with the EV, will enable smooth transition to the technology and components of the future. That is the aim of this project.”

Since then, the project has rolled out accordingly, culminating in the prototype vehicle OVEC-ONE that was featured in The Automotive Engineering Exposition 2013.

Technologies in OVEC-ONE
In the development stage, the team aimed to optimize the structure of the car, gunning for a lightweight body and a decrease in rare metal use. OVEC-ONE showcases a variety of efforts from participating companies. For starters, in developing a versatile in-wheel drive motor, the team set two design conditions for itself: the motor had to fit in a 16” wheel and it had to be compatible with strut-type suspension. The team managed to satisfy both conditions, making OVEC-ONE the first EV with this achievement. In addition, the drive motor does not contain dysprosium, a rare earth element commonly used in hybrid vehicles. This meant that the team also managed to reduce the usage of rare metals. OVEC-ONE was equipped with a solar panel on its roof, and the team selected carbon fiber reinforced plastic (CFRP) as the raw material for the roof, so that it would be 40% lighter than a traditional steel plate roof. Steel plates were used for the battery case so as to enhance resistance to electromagnetic noise, but strength analysis was done to keep them light.

FaroArm Helps Design What’s Beneath the Car Hood
The development of OVEC-ONE was based on Mitsubishi’s Galant Fortis model. To convert it into an EV, unwanted components such as the car engine had to be removed and replaced with other components (e.g. inverter, battery, compressor, heater etc.). The challenge was to layout these 10 new components of varied sizes and shapes thoughtfully in the available space. To ensure that all the equipment fits in the space under the hood, the team acquired 3D data of each item by non-contact measurement using FaroArm. With the 3D CAD data, the team decided on the layout virtually, checking that the components do not interfere with each other. When asked about the design process of the equipment layout, Mr. Shiro Aikawa, Coordinator of OVEC, said, “3D measurement of the various components was necessary as they varied so widely in shape and size. Many of them were hard to measure with a caliper or tape measure. The FaroArm allowed us to efficiently complete the layout of the hood interior in a short period of time.” In fact, individuals from the automotive industry have unanimously expressed their admiration for the EV’s logical equipment line-up beneath the hood.

The FaroArm’s versatility in accessing narrow spaces also proved to be very useful in measuring car interiors. The accompanying photo shows how the FaroArm was used to measure the console box, in order to fit electric components in it. Through the project, the FaroArm has been very useful for measuring items of various shapes and sizes, checking interference, and acquiring 3D shapes for 3D CAD design. In addition, the FaroArm was also used to test the newly designed suspension that accommodates an in-wheel drive motor.

Pressing on Towards Project Completion
The project officially came to a close at the end of fiscal 2013. While its prototype vehicle had already been completed, the team still seeks to implement additional improvements – such as increasing the mileage per charge to 300km. “The purpose of this project was for us to brush up on our skills. We took the lead by getting involved in the development of a new technology. In spite of the difficulties we had to endure behind the scenes, we have no doubt that there is valuable knowledge to be shared,” said Dr. Katsuta about the meaning of the project. Through to the end of the year, participating companies of the Okayama Vehicle Engineering Project for the next EV persisted in the challenge of continuous improvement together, in its technology, products and competitiveness.

About Okayama Prefecture Industrial Promotion Foundation / Okayama Vehicle Engineering Center for the next EV

Launched in 2011, Okayama Vehicle Engineering Project for the next EV was based on the 3 foundational pillars of Manufacturing Technology, Human Resource Development, and Network Enhancement. Comprising a total of 16 participating companies in the prefecture, the project was driven collectively by the wisdom and technology each company brought to the table. Together, the group strived to build an Industry Cluster for the Next Generation Vehicle, in order to enable internationally competitive component production. For the project to remain competitive, the group is committed to continuously challenge and enhance the technology and products that it has developed, all the way till project completion at the end of fiscal 2013.

Techno Support Okayama, 5301 Haga, Kita-ku, Okayama-city, Okayama 701-1221, Japan
Tel: 086-286-9692
Fax: 086-286-9693
URL: http://www.optic.or.jp/ovec/

About FARO
FARO is a global technology company that develops and markets computer-aided coordinate measurement devices and software. Portable equipment from FARO permits high-precision 3D measurement and comparison of parts and compound structures within production and quality assurance processes. The devices are used for inspecting components and assemblies, production planning, inventory documentation, as well as for investigation and reconstruction of accident sites or crime scenes. They are also employed to generate digital scans of historic sites.

With FARO, 3D measurement and documentation needs can be fulfilled confidently. As a pioneer and market leader in portable computer-aided measurement, FARO consistently applies the latest advances in technology to make its industry-leading product offerings more accurate, reliable, and easy to use. The focus is on simplifying workflow with tools that empower customers, thereby dramatically reducing the on-site measuring time and lowering overall costs.

Worldwide, approximately 15,000 customers are operating more than 30,000 installations of FARO’s systems. The company’s global headquarters are located in Lake Mary, Florida, with its European head office in Stuttgart, Germany and its Asia-Pacific head office in Singapore. FARO has branch locations in Japan, China, India, South Korea, Thailand, Malaysia, Vietnam, Canada, Mexico, United Kingdom, France, Spain, Italy, Poland, and The Netherlands.

For more information
Web: www.faroasia.com