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Japanese Society for the Science of Design

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JapaneseSociety for theScience of Design

Original paPer

ReceivedFebruary 16, 2003:Accepted March 7, 2003

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iYIEIBIrcILIE `SwaZ99

Dirk vam G@(}H,Kiyommoto KAWAIKAMll, Yuko IB(AKffZAKI, Hfiroshfi SHllMgZU,

Janstyrm NOIR.IEK, Lammberto MELOTTJ

' Hogeschool Gent Department ef Architecture, Fine Arts and Audioyisual Arti j.Kluyskensstraat 6, 900O GenL Belgium

"

Keio Uniyerstty, Faculty ofEnvironmental lnforrriatien, EV Laboratory, 1 448 Ogura, KawasakL 212-O054;

Japan Science and Technology coiporation, 4-1 -8 Honcho KawaguchL 332-O l 2, Japan.

*""

LDEA Institute, Via Ferrero di Catnbiano 32, 10024 Tcnino, ltaly

Abstract: Socially acceptable elecnic vehicles are required that solve the environmenta1 and energy problemof the traMc, The concept making and design procedure for an electric vehicle was shown to realize a high

performance with new merits. New component technoLogy including Li-Eon battery and original system

technology such as a tandem suspensioli system were invented. These have potential to give high power,comfort and wide space in the cabin in an electric vehicle. A passenger car for high class users in the oMcialapply was seLected to employ these technologies most effectively. An eight seater with a wide flat and lowerfloor cabin design was originated, developed by scale models and a 111 scale mock up was visualircd. Usingthis concept design the final real running prototype electric vehicle was constructed,

The cabin space was 5.25m in length, 1.28m in height and 1.55m in width, which is 1.5 times larger than thatofthe same outer sized internal combustion engine car that is rneasured to be 6.7m in length, 1 .67m in heightand 1.95m {n width. The wheel lay-out of two pairs with distance of 1.45m and two pairs with limiteddistance ofO.7m is calculated for the most effcient seat arrangement upon alimited distance of6,7rn for the 8

passengers. 6 swing doors, crushable zones of O.8m in the front and O.65m space in the rear is situated to

realize the most comfortable and safe packaging design, Moreover the final result ofa high speed electric

vehicle of3 1 1 km/h with its high power of600hp appeared.iKle:y vvords: ConceptDesign, Electric Ylehicle, IVlodeting Protoij{pe, In-Mheel Vbhicle, Li-ion battepy

1. im trod an ctiom

Global warming is ahigh risk [1] for the near future and thecities are polluted by industries [2] and car transportation

exhaust gases [3]. An Electric Vehicle (EV) is an ethcient

solution [4] to reduce C02 and polluted emissions due to cartransportation. Actually an EV is not accepted by the woTldwide public [5] and it is not considered as an important

innovation for transportation. The momentary `EV

image' Esone ofa vehicle of low speed [6], smai1 range and has theanonymeus design ofa converted internal cornbustion

engine (lCE) car. No cloubt that an EV could notyet

introduce its new merits.

To change this `low value EV image' and to show to the

world wide public the rnerits ofhigh eMciency high cornfortand high perfbrmance on a base of innovated designconcept ;s generated for a practical car,

Using this concept an electric vehicle narned `KAZ'

isrealised. In this paper the new desigD concept of an e}ectric

vehicle arid theproce



JapaneseSociety for the Science of Design

2.2Fipme(]ommpormemtTechrmo]ogyTo reach new merits on an EV, new component technologies

are selected and modified: Li-ioen battery, Nd-Fe perrnanentmagnet and Intell lgent power modu]e (l PM) are used.

New Li-ion technology has almost matured in the field ofhandy phones and can even applied to an EV. As Rare Earth

PerTnanent Magnet Groups, Nd-Fe is the best in themagnetic density field's. IPM are to be used as switching

devices in inverters to control the speed ofmotors. Thisrnodule is composed of lnsulate Gated Bipolar Transistor

(IGBT) and integrated circuits. Higher eMciency and

smaller size in inverters was realized.

2.3 Systreffffn TechmollogyTo make it possible to get high perfo rmance and to put newmerits in an EV this new system technologies have beeninvented [8]. As first, theIn-Wheel Driye System (IWDS)was deve]oped where a motor, reduction gears, awheelbearing and a mechanica] brake are assembled in a compactsize and set inside cach driving wheels The mcnits of

IWDS are that rnotor room in the cabin space ofthe vehicle

disappears and can be used for other purposes, energy loss

between a rnotor and wheels is neglectable and the numberof components are decreased in am EV.Secondly the Cornponent Built-in Frame (CBF) is created.In conventional engine caTs there are axles and transm ission

parts under the fioor. When the In-Wheel Drive systern isapplied in an EV all these components are neglected and thespace under the fioor becomes vacant. Moreover a strong

frame structure with a hollow space is put under the fioor.This vacant room is used for instal1ing the batteries and

major components such as inverters and a controller. As a

matter ofconsequence the space ofthe user's cabin isincreased, the centre ofgravity ofthe vehicie is made lowercompared to an ICE car and the weight ofan EV can bedecreased because the framecan be used as a container of

batteries.

The third original teehnology is the Tandem SuspensionSystern (TSS). 0ne 1arge sized wheel is replaced by two

smaller wheels, so that the outer design is changed from a4

wheels car to an 8 wheeis car. The suspension is based on

pairs ofwheels with hydraulic control. Comfort on arough

road is improved, thegrip om the road is doubled, te makesafety while cornering higher the wheelhouse is decreased to

its rninirnum, which makes that the cabin space can beincreased.

Figanreg.TimereIationsammowtgthe]rm-wwdnee)marive,time

ConmpomaermtBmhZt-irmFracrifieaandtheTarmdeff]vSanspepmsfiopm

SYSt¢ pm1

The total system ofthe ln-Wheel Drive System, theComponent Built-In Frame and theTandem SuspensionSystem are shown in Fig.1. These three system technologies

are combined to ensure high performance and give ne}N'rnerits to an EV. The tota1 system is narned

`"1ntegrated

Platfbrm".As is shown in the figure ofthe integrated platform aHcomponents to drive an EV are set inside the frame and the

wheels. As such the space inside the cabin is great]yincreased and the fiatness ofthe floor is also realized.

Moreover, the fioor height is not higher than anoTm a] ICEcar. By the integrated platfonn comfort against vibration can

be increased by Tandem Susp ension System and the motor

itselfdoes not produce vibration. High safety is reached bythe high grip of8 wheels and the lower centre ofgravity.

Finally a high power is realised by an eight wheel drive.

3. Comeept ofVelaicle Type amd Target ttJ sser3.1. Resemrcin of the lFype of tim ce ss'ein icUce

The conceptofan `integrated

platform' cari be applied to

any kind ofautornobile as shown in Fig.2. When applied to a

passenger car it can be comfortable and ensurehigh

perform ance. In a bus or truck wide space for passengersand freights is available. Among these applications a

passenger car is rnost ideal to demonstrate the EV's new

merits for a vehicle.

ltthvaL..

Figanre 2. 0me ancl the sthffnme cimassis vvitla diffletrxemt anser cabirms

fororfi.atrancigbansorpassepmgercar.

28BULLETIN OF JSSD Vol,49 Ne.6 2003 THESCIENCE OFDESIGN

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As target user a choice can be made ofahigh class vehicle, a

middle ciass vehicle or a normal standaTd vehicle, but forKAZ a high class vehicle is selected because the merits of

the integrated platform are useful eneugh for a high classcar. ALI new technologies are expensive when they are

spread and mass production is not easy from the first step.

[9]. Moreover to make it finally possible to facilitate the

absorption of an EV on the tota1 car market the

environmentaI friendly iinage must firstly be shown on the

roadi in an impressive way. Consequently the target users are

the early adopters, coming from the top ofthe user's

pyramid as shown in Fig.3.

ass

ndmrcl

Figan re 3. tamget anser is covrming froffri koigh ¢ Mass

Therefore executives who represent a country like ministers,top politicians, world famous personalities or super

executives ofinternational compan ies who have a positiveopen mind upon the future are the first ones to be selected to

go through EV's new merits and to be convinced about it, so

that afterwards it can be democratized so that everybody

gains by this innovation [1O]. This also happened withother innovated exclusive products }5 years ago [1 ]] forexample the personal computer, the handy phone, the cd-

playerete.

3.2. Sellection of Bem ¢im-MmmkAs a high class EV KAZ must be superior to any other typeof high class ICE vehicle to reach the target ofthedevelopmenta stretched Rolls Royce for 6 peop]e wassetected as abench-mark.

The total length, width and height ofit were 6.5 m, 1.9m and1,55m respectively. The inner cabin aength was in all 3.43Tn,2m for the 4 passengers and O,94m for the driver and co-

driver. The width ofthe inner space was 1 .48rn for the 6

people and the heightwas 1 .09m from the fioor base to the

roo £ Also the fioor was O.36m high forgetting in and

getting off lfthe total outer size ofKAZ is the same as theRo]ls Royce Limousine the total internal size couJd be5.25m Iength with 22m length for the4 passengers in themiddle, 1.6m for the driver and co-driver and 1m length forthe 2 passengers at theback seats. The width is 1.55 m and

the height is 1 ,28 m, As to the imcmial 1ength KAZ is 1.5tirnes longer than the Rolls Royce's stretched limousine.

It means a much vvider cabin room than that ofan RolfisRoyce. Using this sp ace a unique interior arrangememt is

possible in KAZ.The power and weight ratio was estimated at 1hpfkg, From

these measurements we selected the total size that is alrnostthe same as the one ofthe Rolts Royce Limousine.

33. Reqanirerrif] ents for KAZ

The requirements for KAZ were selected as for a high classcar. Because ofthe target user ofhigh class and priorityvehicles using the time more efiectively while traveling isnecessary; a high safety must be guaranteed duTing thetransportation and a positive expression ofan advanced and

pregressive image must be given to thepublic opinion.

4. Waysto Rea]ize the Requ ime]iientss im KAZ4.1. Tfimme Savimg im KAZ.

To save time in acar KAZ should have the function to havea meedng among executives, to take a rest or to relax and todo paper works. Because of the smooth acceleration, the

]ew noise, the low vibration, the wide cab in sp ace and the

fu11 fiat fioor KAZ makes it possible forthe costumer to

reaiize time saving.

4.2. Hfiglm Safety on KAZ

The high safety concerning possib le trathc accideng

possible mechanical trouble and for external violence must

be achieved on KAZ. KAZ can be a high protection against

trafic accidents. Becaatse there is no engifle inside the fronthood. A long crushable zone can be ensured and the effect of

a collision can be minimized in case ofa crash. Its lower

center ofgravity makes not rolling over easy, its huge gripof 8 wheels on the road offers a }imited slip on an icy roadand a stable cornering. Because each ofthe eight motor

receives power from an independent dual battery systeni

under the fleor KAZ can keep going even ifone motor

system or several drive systems encounter sorne or other

trouble. Thanks to the combined system ofa regenerative

brake and a regular brake even mechanical brake will bebroken, KAZ can stop safely by regenerative brake. Andbecause KAZ's steering can be done by mechanica1 steering

aRd by putting difllerent torque to each C{n

wheel motors' lefiand right, even ifrnechanical steering is broken,KAZ can

turn the corner safely by using the torque difference betweenright and left wheels. So, EV KAZ becomes mechariicalayrobust. Moreover, KAZ must be highly protected in case of

external violence. A qenick escape is possible thanks to itshigh acceteration. KAZ is capable to keep driying whensome ofthe 8 vvheels are busted and a stable cornering on a

high speed driving is useful to escape.

THESCIENCE OFDESIGN BULLETIN OF JSSD VoL4g No.6 2003 29

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4.3. Time Adv thrmced arm di Progressfive llumage of KAZ

Even an advanced and progressive irnage in KAZ isachieved: as KAZ is powered by e]ectricity it has an image

ofenvironmenta1 friendliness and expresses a Tespect for ourenvironment, The body design ofthevehicle is flexible so

that it can easily be customised to each user's request. TheinteTior arrangeTnents are completely free so that any kind ofLnterior can be applied. Summing up these features can

already cause KAZ to possibly have a good image.

S. Cormcept Desfigan on Paper apmd Mode]

S.f. Purpose to Use KAZAt first it cari be made for casual use. HeTe its interior and

exterior will be modified for the costumer's sp ecific request.

SecondIy KAZ can be made for famiLy use,Thirdly KAZ can be applied for a formal use where EVKAZ will appear as a priority car for trarisportation of

important persollalities and oMcia




Figu re 7. Seat arma angement of KAZ for a fomvif]a] anse

The main area in the middle ofthe cabin is designed to reach

a wide seat space for 4 passengers like in first class

airplanes and 2 persons in the front and with a seat space at

theback that is also found on norrnal ICE type's, In all 8

passengers ean be seated: 2 bodyguards in the front ofwh ichone is the driver, 4 VIP's in the middle ofthe vehicle and 2

bodyguards in the back.

S.3. Stylmg Design ofthe Exterior of KAZ

The interior seat arrangement and the purpose ofusing itaffect the exterior design. Let us first look at the outerdesign made for the casual type.

On a casual life style a KAZ can express a non traditional

car styling. It can be styled sponively, for exarnple a side

line that is applied around the car which expresses the levelofthe battery content at the outside by means of a green-

yellow line which is much different compared to an ICE car

as shown in Fig.8.Secondly let us take a look at the outer design made for afamily type, When KAZ is applied for famity use it is

required to use the inner space as much as possible,Therefore a big tmnk room and high front nose is designedto make it possible to use the inner room from the first

centimeter in the front to the last centimeter at the back as

shown in Fig 9.Moreover the size ofthe inner cabin room is maximallyequalized with the size ofthe outer cabin of the car.

t.

Figanre 9. exterior diesig- of KAZ for an fami]y ase

ew.

Thirdly the outer design can be adapted to using it as aformal type.As KAZ wiil be used forothcial purpeses a fbrmal useneeds to respect amore traditional line as shown in Fig. 1O.Therefore on the middle height of the vehicte an almost

straight line is giving KAZ amore gorgeous image,A short hood and a short trunk room is designed as eficientcrushahle zone and the huge cabin room expresses EV'sinnovation ofwider space compared to an ICE car,

Especially driver and co-driver as well as the2 bodyguards

at the back should get in and out very easily. Also a quickescape should be possible for all ofthem in case ofan

assault during transportation.Therefore KAZ is also equipped with 2 swing doors for

driver and co-driver, 4 swing doors in the middle ofthe

cabin for the 4 passengers and 2 swing doors for the 2bodyguards.To make it possible to show to the public the image of theintegrated platform the color on the outside shows the imageofthe Component Built-in Frame so th at the publ{c caneasily understand the energy is corning from the floorinstead of com ing from a norrnal motor room.

.tdi.t 'p.t･t'

"･

Figanre g. Exterior of BgAZ for a caspmaD type.

THE SCtENeE OFDESIGN BULLETIN OF JSSD VoL49 No.6 2e0331

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.skv''

Figasre SO. Exteriordesigm ofKAZ for forifrrmaO anse

Taking into account the possibilihes of seat arrangement the

huge choices in exterior design and the final purpose of the

KAZ's concept which is introducing EVs into the carfnarket, using KAZ for formal use is seaected. Because it is

indispensable to show first ofal1 EV's merits to important

people corning from the high cllass agid to respond first of ala

to their transportation needs in the hope they wilg be

convinced by EV's advantages.

S.4. ()opm¢ ¢ pt Desfigan of tinue Wimee] Leny-oast om the

Claanssis.Although the wheel size ofthe integrated platforTn issmaPer thagi the cenventional 4 wheel car the whee1 houses

still efit:ct the inside ofthe cab in. For th is reason the most

eficient wheel arramgernent has been invented.

J pm this research three types ofwheel lay-out have beenconsideTed. The chassis can be designed according to the

fo11owingprinciples:firstly two times two pairs ofwheeis with limited distance in

between; and secondly two times two pairs ofwheels with

distance in between; amd thirdjy two pairs ofwheeis with

distance and two pairs of wheels with limited distance iem

between as shown in Fig.1 1 a, b and c respectiwely.Taking

into account that 4 passengers in the middle are normaa forKAZ's formal use amd given the fact that getting in and

getting offvery quick ity is important for the two bodyguards

in the front and at theback two pairs ofwheels with distance

and two palrs with

a)

b)

/s

' ua-yy

tmx:.twy.marm..as

c)

Figanre ll.Tinree types of wim eeNay-oantofKAZ

lim ited distance in between is decided upon the mest

eencientlay-out ofthe chassis, Thanks to this lay-out driverand co-driver can be set very close to the front of the car, so

that the cabin space can be used ediciently for a total of 8

passengers.

5.S. ¢ on ¢ ept Desagm by Modie] MakimgFirstly 1f20 scale models were rnade so as to search anice

innovative image for an EV powered by 8 wheels vvith a

length of6.7 m and ofwhich the shape is very different fromanormal ICE car. Finally there is a lot offreedom for the

designer to gnvent styling for an EV. As shown in Fig.12many types ofstyling design for casual, family and formal

type were made.

-･ t

/.t {･ kl･1 L･-

f"'"' "'

uFigasre 12. waZ"s ffgoodels timat eMpresses aan EV iiifmage

32BULLETIN OF JSSD VoL49 No.6 2e03 THESCIENCEOFDESIGN

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These modeLs were rn ade to verify the firstly in ade sketches

and were rendered in real 3 dimensional shapes. Besides theimage ofahuge cabin space the search foralower

aerodynamic shape and its nice positive image of

environrnent-friendliness was developed on these3

dimensional tnodels as well.

Fig an re 13. 1fl O scab]e iTDodel of KAZ for a forvtrna] an se

Secondly after having combined the anthropometrical datafor a vehicle of8 passengers with KAZ's iniage on a formal

use the global packaging design is made on 111O scalemodel as shown in F{g,13,

Finally a 111 scale mock up is made to verify the highcomfort that must be reached for the 8 passengers and to

check the seat space efficiency which is shown in Fig.1 4.

Ffiganre 14. Moek anp orm lfl seafie

In the end this was made possible by a 6.7m long multi

purpose EV where O.6rn is foreseen as 'crash

ifnpact mone' in

the frong 1 .4m for the steering post with co-driver, 2.3m forthe V.I.P. space for 4 persons, 1m forthe bodyguards in theback and finally 1 ,2m as luggage roorri. Also the place of theg wheels is carefu11y chosen: 2 pairs an the front with a

distance in between of l 45cm and 2 pairs close to each

other at the back with a clistance in between of 70cm so that

a smooth entering and getting off are rnade possible within a

compact cabin volume.

6. (]onstranctfiom oftloe "KAZ"

Comcept"

6.1 Timce Ran amanimg Man]e ofKAZGiven the above narn ed purpose of usi"g one and the saTnechassis for different user cabins for EV KAZ, given theconceptofseatarrangernentandtheconceptofwheel]ay-

out for KAZ on a formal use, the `Component Built-In

Frame chassis' is constructed as the fioor base for dithrent

possibilities. As the first step ofrealisation ofthe KAZ's

concept, the 'Running

Mule' ofthe KAZ's chassis is

realised by I.DE.A Instimte in Torino.Figure 15a shows the structure ofthe mule and Fig 1 5b isthe scene oftest run to verify the concept ofthe integrated

platfbrm.

a)

b)Figume lg. Tlme rannnipmg Fr)an ]e.

Afterwards, the reliability ofthe KAZ's chassis could betested, the outer and interior design as welt as the seatarrangement and door concept could be considered frorn this

runningmule.

6.2 The Ontem Styiimg Destgm oif KAZ

Given the body structure and the chassis ofthe running

mule, 8 different styiing designs are proposed and finally 3

have been selected, as are shown in Fig 16. The fact thatalot ofuser space can be made use ofa limited measure, KAZ

as a height ofl,675m high, a length of 6,7m, 'and a width of

1,95m for8 passengers.To give expression to the ]ong hood that is replaced by theconcept ofthe immediately available user space, KAZ isalmost styled by the short and high nose and the front spaceis used as a erushable zone.

The final selection ofstyling design is the image ofa more

classy car as shown in Fig.16 below, this KAZ's type isshowing clearly the 8 wheels, without a wheel-cover

THE SCIENCEOF DESIGN BULLETIN OF JSSD VoL49 No.6 200333

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because as a first prototype, it must expresses a rea] car

image. Besides the target users aren't used to dTive cars with

apm upmconventional car sty]ing.

a)

b)

.t../t.in-t.. ...tetttt...tt. .t

it,,;g.:.ks:z･tr,g'ee.dwtt'/ee/1fiagl,i･g,s.g･ ,.tttsmsu ttt .

c)FiganTe

16. Tin ree seiecthed ssty"img desigpms for waZ: a, b en c

6.3 Ipmpmer Stylmg D¢ sfigm of KAZ

Based on the above mentioned concept ofseat arrangernent

for KAZ's formal type as well as the concept ofthe whee1

'Z..f'Sc,s'ff,c･i''i'i''//'1"}"//tl=!-.=-t･==･t-.------

t..t...t.t.t.t...tt..t...t./tt,Lt"

f""'t'/""'ittttttttttt/ttttttttlt/tttttttt'/.....tt.ae.-.I,･le'i'"xl-,

.tr.t/N.tt'11,/--x,x:i.,/,,vrl-･t.･tl.sl,tttttttttt--･･-･･lt

Q'iOi'tttttlpm-

a)

lay-out on the ghassis the final seat arrangement is set as

shown in Fig.17a.

The firm al doer concept of6 swEng doors for the g passengersand the two applications ofthe working space as shown in

Fig.17b and the living space are set in the KAZ vehicle for

formal use.

6.4 Prodianctioam at lfS scaUe minode]

Starting from above mentioned styting designs a 115 modelwas rnade to verify the impact ofthe styging on a three

dimensional volume. Consequently the door cencept of

KAZ can easily be changed so that in the first prototype two

swing doors are selected as shown in Fig 18.

Fignnre 18. 1/S scale rrif]o{gel of the styliang diesigpm

6.S Detmfiaed Dessigm ofFfirme Pfl rts an re Madle

Fo1lowing the main strearn ofglobal packaging design thefront beaEns, the lamps on the rear and the design ofthe dash

board panel are cornpleted. Aftervvards from the styling of

the 1 15 model a scan is made and the full scale base model is

set up by software. Parts are produced in polyester, the

globa] structure is realized and the final KAZ is assembledas shown in Fig. 19 and Fig20, The user's cabin ofKAZ isset on the saine chassis as the

`Tunning

mule' which is made

for testing the concept.

1,

Figosre19.ThepoeyestempmrtofKAZ'sfromtmtnheZeft

b)

Figanre17.FirmenOiantemiordicsigan

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