Sunarto Kaleg

Light-weight sandwich panel honeycomb core with hybrid carbon-glass fiber composite skin for electric vehicle application

The carbon fiber reinforced plastic (CFRP) composite is relative high cost material in current manufacturing process of electric vehicle body structure. Sandwich panels consisting polypropylene (PP) honeycomb core with hybrid carbon-glass fiber composite skin were investigated. The aim of present paper was evaluate the flexural properties and bending rigidity of various volume fraction carbon-glass fiber composite skins with the honeycomb core. The flexural properties and cost of panels were compared to the reported values of solid hybrid Carbon/Glass FRP used for the frame body structure of electric vehicle. The finite element model of represented sandwich panel was established to characterize the flexural properties of material using homogenization technique. Finally, simplified model was employed to crashworthiness analysis for engine hood of the body electric vehicle structure. The good cost-electiveness of honeycomb core with hybrid carbon-glass fiber skin has the potential to be used as a light-weig...

1P15S lithium battery pack: Aluminum 5052-0 strength of material analysis and optimization

The electric vehicle energy source comes from electric energy stored in a battery unit. The battery unit composed of battery cells which have connected series or parallel or combination of both and placed in a component called battery pack. Battery pack is mechanical assembly comprising battery cells and retaining frame or trays, and possibly components for battery management. Battery Management System (BMS) requires battery pack design which have the ability to support battery cells mass and its support components. Battery pack design is involving strength of material analysis to know stress response that occurs on the structure due to components mass in it. The strength of material analysis use Finite Element Method (FEM) (Von Mises equivalent stress combined with Allowable Stress Design (ASD)) to get optimize design based on the most optimum material thickness. The battery pack Computer Aided Design (CAD) made to 15 pieces battery cells with no parallel and 15 series format (1P15S) and its support components so load occurring on the battery pack is 1,250 N. The result of container shaped of aluminum 5052-0 battery pack design shows that stress concentration occurred in base of the battery pack, with maximum Von Mises in the area around the battery pack base with vehicle frame. Furthermore, the optimum battery pack design is using 2mm material thickness and the optimal mass is 6.51 kg.

Vibration-Damping Factor of Glass/Kenaf/Polyester Hybrid Composite

The study of vibration-damping factor on unsaturated polyester resin reinforced glass and kenaf fiber has been performed. Two variations of glass and kenaf fibers were made based on fiber volume fraction (Vf) and ratio of glass to kenaf fiber at Vf of 25 %. The measurement of the samples was to obtain the value of the vibration-damping factor and the elastic modulus. The result shows that the vibration-damping factor decreases proportionally to the addition of fiber. Increased stiffness is evidenced by an increase in elastic modulus along with an increase in fiber content. According ratio of glass to kenaf fiber, the vibration-damping factor decreases proportionally with the increasing of glass fiber content. Increased kenaf fiber content causes an increase in vibration-damping factor, a decrease in elastic modulus, and lead to decreased in stiffness of the hybrid composite.

Finite element analysis of electric bicycle frame geometries

This paper presents a simulation Finite Element Analysis (FEA) model of electric trike frames. The model of electric trike frame is a standard bicycle frame with addition modification on the back side for battery pack component and passenger loads. The electric motor is driven to put in front wheel for easy maintenance. Due to gain maximum safety in the passenger area and easy assembling, the frame is manufactured by circular steel tube in the front side and square steel tube in the back side. FEA simulation has been investigating proper model based on steel tube profile. The profiles is circular and oval steel tube 1.65mm thickness, (1, 1 ½, and 1 ½) inch diameter in front and square steel tube 2u2005mm thickness, (30×30, 40×40 and 50×50) mm size in the back. The support tube of the electric bicycle frame is similar to the National Standard road bicycle (SNI).The validation of this simulation is using experiment method and adaption method for optimizing iteration time and accuracy. The result of the simulati...

A development of smart metering infrastructure for Electric Vehicle charging point

In this paper proposes the design and development of a smart metering infrastructure to handle the charging process in Electric Vehicle (EV) public charging point. Charging point is needed to simplify the process of electric energy charging for EV and increase the flexibility of the use of EV in public. Charging point for use in public places has some security systems and information displayed according to user needs. This paper described the development of public charging point that have a smart metering to serve the purchase of electric energy as the user desires, to monitor the use of energy that transferred, shut down the system when problems occur, stop the charging process of electric energy when it reaches the appropriate number on the purchase, and save data usage that needs for further analysis. The system uses electrical energy calculations kWh meter that meets the standards of measuring instruments, the measurement accuracy is up to 0.5 Watts. This charging point uses a microprocessor system as a data processor and displays it onto a 15-inch screen as a user interface. Purchasing system using a smart card that stores user data and possessed of balance.