Car makers nowadays make sure that each of their creations are not only equipped with superior engines but also designed aerodynamically. These two factors, when achieved can make a vehicle perform excellently and economically as well. Lotus Engineering knows this for a fact that is why it came up with a study that reducing a vehicle’s weight can help boost its fuel efficiency. Lotus Engineering worked with Council on Clean Transportation for the said study. According to their estimates, a vehicle can have as much as 23% fuel by simply shaving off 33% from its entire mass.
The vehicle used as the basis for these findings by Lotus and CCT is the Toyota Venza. The Venza was really taken apart, weighed, and examined part by part to comprehend components masses and to come up with a bill of materials. The specific parts examined were the body, fenders/closures, thermal, bumpers, electrical, interior, lighting, suspension/chassis, and glazing. The interior and exterior dimension was not altered.
Here are some excerpts from the study released by Lotus and CCT.
Closures/Fenders
The closures include all hinged exterior elements, for example, the front and rear doors and the rear liftgate. One alternative approach included fixing the primary boot section to improve the structure, reduce masses and limit exposure to high voltage systems. A lightweight access door was provided for checking and replacing fluids.The closures on the baseline Toyota Venza were made up of 100% steel. The low mass Venza closures/fenders would be made up of 33% magnesium, 21% plastic, 18% steel, 6% aluminium with the other 22% consisting of multiple materials. The mass savings are 41%, a reduction from 143 kg to 84 kg.
Chassis/Suspension
The chassis and suspension system was composed of suspension support cradles, control links, springs, shock absorbers, bushings, stabilizer bars and links, steering knuckles, brakes, steering gearbox, bearings, hydraulic systems, wheels, tires, jack and steering column.The chassis and suspension components were downsized based on the revised vehicle curb weight, maintaining the baseline carrying capacity and incorporating the mass of the hybrid drive system.
The total vehicle curb weight reduction for the 2020 vehicle was 38%, excluding the powertrain. Based on the gross vehicle weight, which includes retaining the baseline cargo capacity of 549 kg and utilising a hybrid powertrain, the chassis and the suspension components were reduced in mass by 43%, with projected cost savings of 5%.
Front and Rear Bumpers
The materials used on the front and rear bumpers were very similar to the existing model to maintain the current level of performance. One change was to replace the front steel beam with an aluminium beam which reduced mass by 11%. The use of a magnesium beam was analysed but at the current time exceeded the allowable price factor.Heating, Ventilation and Air Conditioning
The air conditioning system was integrated into a passenger compartment system and an engine compartment system. This section addressed the under hood components which included the compressor, condenser and related plumbing. The under hood components were investigated for technologies and mass.The study showed a relatively small mass difference for the underhood air conditioning components based on both vehicle mass and interior volume. Because of the highly evolved nature of these components, the requirements for equivalent air conditioning performance and the lack of a clear consensus for a future automotive refrigerant, the mass and cost of
the Toyota Venza compressor, condenser and associated plumbing were left unchanged for both the 2017 and 2020 models.Electrical/Lighting
The estimated mass savings for using thinwall cladding and copper clad aluminum wiring, as used on the 2017 model was 36% versus the baseline model. The lighting technologies section reviewed included diodes, xenon and halogen. The study also reviewed a variety of wireless technologies under development for non-transportation applications that could be used in this time period pending successful development for mobile applications.
Source: Autoblog














