Abstract:

Modularity is a design approach where vehicles are constructed using distinct, separable units or “modules” that can be independently developed and assembled to serve across different sizes and shapes of vehicles. This design philosophy means that each module operates independently or is nearly functionally isolated and has the least dependency on other modules. By integrating various modules of different capacities or specifications, manufacturers can offer vehicles with diverse performance levels, features, and capabilities, allowing customization and scalability in vehicle production. This approach allows car manufacturers to streamline production, reduce costs, and increase the flexibility of their product offerings. The objective of the paper is to propose a passenger car electric vehicle modular strategy using Giga-castings and structural battery pack.

In today’s world of auto manufacturing, a car or large SUV can need as many as 30,000 parts to become a whole vehicle. A car can take between 17 and 18 hours on the assembly to complete once separate suppliers make all those parts.

The parts that go into a module are assembled before shipping off to the automaker in Modular Design. Then they take all the modules and put them together to build a car. Modular manufacturing allows car manufacturers to streamline production processes, reduce waste and increase efficiency. It gives OEMs an upper edge by providing them with improved flexibility of product offerings, faster production times, improved quality control, simpler aftermarket maintenance and repairs, reduced environmental impact and greater innovation.

With Automotive OEMs focusing on Net Zero emission & sustainability there is a need for manufacturers to focus on Electric Vehicle Manufacturing and expanding their EV offerings using adaptable and scalable platforms.

KPIT proposes a passenger car electric vehicle modular strategy using Giga-castings and structural battery pack. This strategy involves the development of versatile and adaptable modular platform, serving as the foundation for a variety of vehicle designs. In electric vehicles, multiple wheelbase options and body sizes with diverse performance requirements can be constructed on the same platform using modular approach.

Figure 1: Various Vehicle Class and Wheelbase, and Drive

Some of the key benefits for OEMs using Modularity with Giga Casting in EV manufacturing include-

• Its Simpler due to less part complexity up to 170 parts can be reduced to 2
• Manufacturing is Cheaper by up to 30 % than its legacy methodologies.
• It’s Lighter by up to 20 % than its legacy version.
• Innovation opportunities in front & rear casting, assembly line, overhangs and seating comforts.

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