| ROADLITE | This project is in progress |
| Research, Development and Demonstration of a Lightweight, Chassisless Composite Semi-trailer |
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Introduction
Road haulage is by far the most important form of transport for goods in Europe and is expected to grow by 25% over the next 15 years. HGVs account for approximately 10% of the total European energy consumption, contribute over 30% of total CO2 emissions and cause damage to roads and bridges. Therefore as vehicle weight / inertia accounts for a significant proportion of fuel consumption and CO2 emissions, the use of lightweight materials and construction techniques are becoming increasingly important. Aims The overall aim of the research is to develop the design and processing methodologies necessary to manufacture a lightweight composite semi-trailer. Using innovative integrated design techniques (i.e. CAD/CAM and CAE) and novel vacuum infusion manufacturing processes this project aims to produce an alternative to the heavy and labour intensive steel chassis that are currently used. Specific objectives of the project include: ·To compute an HGV design, which is lightweight, aerodynamic and multi-functional (i.e. boxed, flatbed, curtain sider etc.). ·To examine and specify the most appropriate type of processing and materials to be used in the construction of the trailer. ·To manufacture and assemble a prototype composite HGV for extensive evaluation trials on a test track in order to quantify its operating performance, functionality etc. ·To undertake a cost benefit analysis and comparison with conventional trailers. Research Extensive market research by Southfields Coachworks Ltd. took place to determine the most appropriate case study for this project. This showed that a 9750 mm urban articulated trailer (28 tonne GVW) offered the most practical demonstrator in terms of technical, environmental and commercial exploitation. A traditional steel trailer of this type was manufactured and underwent accelerated dynamic testing at the Leyland Technical Centre (LTC). A design for a composite HGV trailer has been coordinated by Europrojects (LTTC) Ltd. The approach was based on classical laminate design and composite theory merged with simplistic FEA to reduce design cost. Glass/polyester composite was chosen to provide good structural performance whilst keeping within commercial budgetary constraints. The design has been kept uncomplicated to enhance its ease of production, use and maintenance. The trailer has been moulded by Halmatic Ltd (Part of Vosper Thornycroft Ltd) using the vacuum infusion technique. Small-scale trials were performed to aid the understanding of the vacuum infusion system prior to the manufacture of a full size prototype mould. Moulding of the full size 10m composite HGV trailer has been performed with the assistance of the University of Nottingham who developed systems to aid the moulding process. Models to predict resin flow in the vacuum infusion process have been researched and developed and used to map out the gating and porting arrangements for the moulding of the composite trailer. Southfields Coachworks Ltd have assembled the necessary running gear and attached the required ancillaries onto the trailer in order to make the trailer operational. The trailer has been instrumented with strain gauges and has been tested under normal load and manoeuvring conditions at Leyland Technical Centre Ltd. The first prototype composite trailer is over 350kg lighter than its steel equivalent and the tests showed the trailer to be strong enough to withstand 23tonne concentrated loads. Issues have been learnt from the first prototype however and a second design is under development with an anticipated weight saving of over 500kg. Final Outputs Final outputs from the research will be at least two working prototypes of the trailer along with test data, design details and cost analyses of composite trailers for urban use. In addition, those involved in the project will have acquired the know-how to design, develop and manufacture trailers of differing sizes for various other applications. Participants Euro-Projects (LTTC) Ltd Southfields (Coachworks) Ltd Halmatic Ltd LTC Ltd University of Nottingham |
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