The research project HylightCab is focusing on hybrid lightweight construction. This picture shows a generic lightweight roof module.
Fraunhofer-Institut für Chemische Technologie ICT
Vehicle weight is still the dominant factor in fuel consumption, especially when it comes to commercial vehicles. According to statistics portal Statista, much of the world's CO2 emissions stem from goods transport, over 70% of which is handled by trucks. As part of the HylightCab research project, engineers from research and industry are now aiming to achieve a cost-effective weight reduction of 30% compared to previous steel designs. This project is focusing on hybrid lightweight construction and the commercial vehicle’s cab structure.
In order to advance hybrid lightweight construction, the engineers are specifically researching highly stressed components of the truck cab, i.e. the cab structure. For highly stressed areas in the cab, hybrid material production processes should lead to a significant, yet affordable, weight reduction. In the medium term, the aim is to make multi-material design ready for mass production. For this purpose, various multi-material components will be developed and integrated into the cab structure. Components currently produced by conventional means will gradually be replaced by the new design.
Research is focusing on joining technologies
This application-oriented approach focuses research on system integration in a vehicle, including the associated joining technologies, and is intended to facilitate rapid implementation. In addition, future cab requirements such as changed crash requirements and alternative drive systems will be considered. Structural and process simulations secure and maximise the lightweight construction potential in the development process.
In addition to the planned weight reduction of 30%, the developed solutions are designed for smooth implementation in ongoing production in order to be ready for series production in the fastest time possible. Besides reducing fuel consumption, the commercial vehicle's lightweight design also offers a further benefit: reducing the unladen weight allows an increase in the maximum possible payload for the permissible total weight, which in turn reduces the number of trips. Lightweight construction in commercial vehicles therefore conserves resources while increasing efficiency.
HylightCab project partners
The German Federal Ministry of Economic Affairs and Energy is funding the HylightCab research initiative as part of the “New Vehicle and System Technologies” programme, which ends in May 2020. Leutenbach-based GreenIng GmbH & Co. KG is the research consortium's coordinator. The project partners also include Fraunhofer ICT – Fraunhofer Institute for Chemical Technology, Pfinztal; FAST Institute of Vehicle System Technology FAST – sub-Institute Lightweight Construction Technology at Karlsruhe Institute of Technology (KIT); Fritzmeier Composite GmbH & Co. KG, Bruckmühl; and Christian Karl Siebenwurst GmbH & Co. KG Modellbau & Formenbau, Dietfurt a. d. Altmühl in Germany.