Understanding New Security Connotation and Decrypting Extreme Fox Automotive Battery Hard Core Technology

At the Tianjin Auto Show, which opened on September 29th, Polar Fox Motor held an extremely intelligent and safe battery security decryption activity-Polar Fox Technology Day. Through a series of interpretations of vehicle architecture and automotive battery hard core technology, users can re-understand the brand-new safety connotation given by ARCFOX Extreme Fox.

Three advantages and battery safety

Endurance anxiety and battery safety are the most frequently mentioned problems about electric vehicles by consumers. So, on the two issues that users are most concerned about, how does Extreme Fox make everyone drive safely and use it safely? First of all, about cruising range. NEDC, the long-range version of Alfa S, has a cruising range of 708 kilometers, which is the longest production model on the market at present. For this purpose, polar fox does not blindly increase the number of batteries, but pursues the ultimate utilization of energy, and adopts the combination of "lightweight, high efficiency and fine control" to achieve long cruising range.

In terms of light weight, the fox car is made of steel and aluminum. The lightweight coefficient of Alfa T body 1.78, and the lightweight coefficient of Alfa S body 1.6 are leading in the industry. The lightweight level of battery pack can be evaluated by the index of system energy density. The maximum energy density of the battery pack is 194 Wh/kg. Compared with the industry average of 160 Wh/kg, under the same 93.6kWh battery pack, the battery pack of Extreme Focus can save 100kg in weight and increase the cruising range by about 30 kilometers. The realization of high energy density benefits from the energy density of 280Wh/kg battery, the structure of high specific strength aluminum profile and the weight reduction strategy of integrated scheme.

In terms of high efficiency, the electric drive system of polar fox has been optimized repeatedly in electromagnetic design, transmission scheme, lubrication simulation, coupling integration and so on, ensuring the same first degree of electricity. The polar fox can be converted into the kinetic energy of the vehicle in a high proportion, and the highest working efficiency is greater than 93.5%. In the case of the same power, the battery life can be improved by 3%. Single pedal (single pedal mode) and Ibooster can achieve efficient energy recovery, and the energy recovery rate reaches 26% under comprehensive working conditions.

At the same time, Polar Fox's vehicles are also equipped with a new generation of IBTC intelligent bionic thermal management system, which can dynamically follow the changes of users' time habits, driving distance habits and environmental temperature. , intelligently calculate the opening time and threshold of insulation heating, and protect the power battery at constant temperature after fast charging or slow charging. The battery system itself has good low temperature performance. At the low temperature of -7℃, the energy retention rate of polar fox battery is 92% of that at room temperature. Even in the extremely low temperature environment of -20℃, the battery discharge is still above 85%.

As we all know, in the event of a collision, strong impact and body deformation will cause harm to drivers and passengers. Compared with the "physical injury" of fuel vehicles, pure electric vehicles also have the risk of chemical injury and electrical injury. Therefore, polar fox also attaches great importance to the safety of battery packs. In order to prevent the deformation of the whole vehicle from being transferred to the battery system during collision, which leads to fire and other major problems, the layout scheme of the power battery is considered in the design and development of the body and chassis of the polar fox automobile, and the battery pack is defined as a safe and deformation-free area like the passenger compartment, with heavy protection. When the vehicle encounters rear-end collision or side collision, the buffer zone and deformable zone around the battery pack are designed to absorb external force to reduce the damage to the battery pack caused by collision.

The buffer zone and the deformable zone protect the battery box, and the battery box protects the battery cells. Therefore, the design of high-strength box is also a key link. Around the battery module (energy module), we have arranged four horizontal and one vertical reinforcing beam structures, just like packing a battery with a keel shell and a vertical and horizontal interwoven three-dimensional structure, which decomposes and absorbs external impact energy and protects the cells in the battery pack from impact.

As we all know, in the event of a collision, strong impact and body deformation will cause harm to drivers and passengers. Compared with the "physical injury" of fuel vehicles, pure electric vehicles also have the risk of chemical injury and electrical injury. Therefore, polar fox also attaches great importance to the safety of battery packs. In order to prevent the deformation of the whole vehicle from being transferred to the battery system during collision, which leads to fire and other major problems, the layout scheme of the power battery is considered in the design and development of the body and chassis of the polar fox automobile, and the battery pack is defined as a safe and deformation-free area like the passenger compartment, with heavy protection. When the vehicle encounters rear-end collision or side collision, the buffer zone and deformable zone around the battery pack are designed to absorb external force to reduce the damage to the battery pack caused by collision.

The buffer zone and the deformable zone protect the battery box, and the battery box protects the battery cells. Therefore, the design of high-strength box is also a key link. Around the battery module (energy module), we have arranged four horizontal and one vertical reinforcing beam structures, just like packing a battery with a keel shell and a vertical and horizontal interwoven three-dimensional structure, which decomposes and absorbs external impact energy and protects the cells in the battery pack from impact. In addition, the integrated thermal management system with dry and wet separation can ensure the safety of electricity consumption. Ceramic fiber fire blanket is equivalent to putting a fire suit on the battery and blocking the fire source.

As a product with pure electric architecture based on forward development, the overall design of the power battery of the polar fox product is integrated into the design and development of the body and chassis. Through 26 connection points, the power battery is closely connected with the whole vehicle, which ensures the overall rigidity of the vehicle body and improves the safety of the battery. In more than 65,438+0,000 hours of simulation test and more than 65,438+0,000 rounds of actual test under more than 20 collision conditions, the power battery is not damaged, which ensures that even in the case of collision of polar fox brand products, the battery will not be deformed due to collision, resulting in major problems such as fire and failure.

Physical safety

At present, there are three main schools of automobile body materials, namely all-steel body, all-aluminum body and steel-aluminum mixed body.

The advantages of all-steel body are that the body structure is strong enough, the scheme is mature and the cost is relatively low; The all-aluminum body structure has performed well in the aspect of light weight, which greatly enhances the friendliness of new energy vehicles that attach importance to endurance. However, due to its own material characteristics, the maintenance cost of all-aluminum body after collision is too high, which can not meet the safety pursuit of higher strength; The steel-aluminum hybrid body combines all the advantages of the above two. Through the reasonable application and distribution of materials, the lower car body is made of aluminum alloy, which realizes light weight, ensures the absorption of collision energy and the transmission of collision force, and the upper car body is made of steel with different strengths, which realizes high strength and collision safety. Finally, the steel-aluminum hybrid body continues the lightweight characteristics of the all-aluminum body, making the body structure safer and balancing the production cost and maintenance cost of the all-aluminum body.

The polar fox car was born on the basis of IMC platform architecture. On the basis of ensuring the excellent performance of the chassis, the battery layout design space is provided to the maximum extent, which can realize the expansion of different wheel tracks and wheelbase and meet the multi-vehicle planning. At the same time, the IMC platform architecture matches key technologies and systems such as high performance and high security, and has a highly intelligent electronic and electrical architecture and an upgradeable OTA cloud service, which ensures the rapid iterative research and development capability of new products of Extreme Focus.

The products of polar fox are developed based on the newly built IMC platform architecture, and a large number of excellent designs and advanced concepts are applied. The body design adopts different materials and manufacturing processes according to different regional characteristics, giving consideration to both weight and performance. Ultra-high-strength thermoformed steel beams with the strength of 1500MPa are applied to A and B columns and doorsill, and a "cage frame" body structure is formed through the design concept of "structural ring", and the whole structure participates in bearing collision energy, thus ensuring the integrity of the passenger compartment during collision.

On the side of the car body, the polar fox adopts the innovative concept of the sill load-sharing beam, and adopts the design of combining the steel sill with the aluminum extrusion profile. The safety distance of the battery is 3.7 after the side column collision, which is much higher than the national standard ≥0. At the position of the front sub-frame, the polar fox adds the design of collision energy absorption structure, and the whole frame structure of the front sub-frame cooperates with the multiple collapse guide groove structures on the longitudinal and transverse beams, so that the front sub-frame can participate in absorbing collision energy when the vehicle collides.

According to the position of the front longitudinal beam, Polar Fox first developed a new aluminum alloy material with higher yield strength and collision and collapse bending angle above 1 10, which far exceeded the national standard requirements and met the engineers' requirements for folding and energy absorption of the front longitudinal beam.

Because of the different characteristics of aluminum alloy materials and steel materials, it is impossible to connect them by traditional welding technology. In order to solve this problem, the combination of SPR (self-piercing riveting process), FDS (hot-melt self-tapping thread connection process) and adhesive bonding is applied in the Magna Factory of Blue Valley of Polar Fox, which makes the connection between materials more stable and realizes the perfect connection of steel and aluminum materials. Take the Extreme Fox Alpha S as an example, 1276 SPR locking and riveting screws, 430 FDS flow drilling screws and high-strength structural adhesive exceeding150m are applied to the car body. The extensive use of these advanced connection technologies not only improves the rigidity of the car body, but also makes the air tightness of Alpha S reach 58SCFM.

It is particularly worth mentioning that the torsional stiffness of polar fox products has reached a very high level: the torsional stiffness of Alfa T body has reached 55,000 nm/0, and that of Alfa S body has reached 60,000 nm/0. The high torsional stiffness of the car body can optimize NVH performance, reduce the occurrence of fatigue damage and abnormal sound of the car body, and ensure the handling stability and collision safety of polar fox products under various working conditions.

As mentioned above, the technical requirements of steel-aluminum hybrid car body in production are very high. The steel-aluminum hybrid body of Polar Fox is produced by Blue Valley Magna Factory. Magna enjoys a high reputation in the field of vehicle manufacturing. It is itself a manufacturer of many international first-line high-end brands such as Mercedes-Benz G, new BMW 5 Series, Jaguar E-PACE and i-PACE. Blue Valley Magna Factory is Magna's first joint venture factory in China. Magna Mafact production system has been fully introduced, which has laid a solid foundation for the good quality and workmanship of polar fox.