15 seater Electric van 

Introduction

Electric vehicles (EVs) have become increasingly popular due to their environmental friendliness and energy efficiency. 

Australian Company   i602 Pty Ltd , has designed and fabricated the first prototype of a 14-seater electric van. This vehicle has been presented in many exhibitions and showcases, attracting the attention of potential customers and investors. 

The i602 electric van boasts a range of advanced features and technologies, including a high-performance electric powertrain, an innovative battery management system, and a spacious and comfortable interior. With the increasing demand for sustainable transportation solutions, it is likely that electric 14-seater vans will become more widespread in the market, and companies like i602 will play a crucial role in shaping the future of this industry in Australia.

What is done so far

Designing an electric 14-seater van from scratch involves several stages that must be followed for the successful completion of the project. Here are the several stages involved in designing an electric 14-seater van in i602 pty Ltd from scratch:

I- Research and Conceptualization: 

The first stage was research and conceptualization, where the team identified the target market, determined the requirements for the vehicle, and developed a concept for the van's design. This stage involved gathering information about the latest technologies and trends in electric vehicle design and identifying the unique features that the vehicle should have.

II- Design and Development: 

The second stage was  the design and development of the vehicle. This stage involved the creation of detailed drawings and 3D models of the vehicle, which guided the fabrication of the van's components. In this stage, the team also designed the powertrain ,battery configuration, mechanical and interiors for i602 electric van.

Interior design:

Designing the interior of an electric 14-seater van requires several necessary stages to ensure safe, comfortable, and practical usage. The following aspects need to be considered:

Location of the sliding and plug passenger door:

The position of the door should be easily accessible to the passengers, preferably on the side of the vehicle. The door should also have a suitable opening width for the passengers to enter and exit the van comfortably.

Safe allocation of the swappable batteries:

The batteries need to be placed under the passenger seats to provide enough space for the passengers and their luggage. The battery compartment must be safely secured to avoid any accidents.

Comfortable and safe seating:

The van should have comfortable and safe seats for passengers to sit in. The seats should have proper cushioning, headrests, and adjustable features. The seats should be easily removable for added space.

Easy accessibility for passengers:

The van should have an easy-to-use step and grab handle for passengers to enter and exit the vehicle safely. The van should also have proper lighting inside for clear visibility.

Lighting, air conditioning, ventilation, and multimedia:

The interior of the van should have proper lighting and air conditioning to ensure passenger comfort. The van should also have a ventilation system that can keep the air inside the van fresh. The van should have a multimedia system for entertainment.

Driver seat and ergonomics:

The driver's seat should be comfortable and have adjustable features for the driver's comfort. The dashboard should be user-friendly and easy to access, with all the necessary controls within reach. The driver's seat should also have proper visibility of the road and the passengers.

Mechanical components:

Designing an electric van requires careful consideration of various mechanical components, including the chassis, suspension, power train, battery, electric motor, durability, and stability. In this paper, we will discuss the key parameters required for designing the mechanical parts of a 1500kg electric 14-seater van.

Chassis:

The chassis is the backbone of any vehicle, and its design determines the vehicle's strength, weight, and handling. A 1500kg electric 14-seater van requires a robust and lightweight chassis made of high-strength materials such as aluminium, carbon fibre, or steel. The chassis must be designed to withstand the weight of the battery, motor, and passengers. The chassis design should also consider the aerodynamic drag and provide ample space for the battery and motor.

Suspension:

The suspension system of a van is responsible for ensuring a smooth ride and handling, reducing vibrations, and absorbing shocks from the road. For a 1500kg electric 14-seater van, the suspension system should be designed to handle the weight of the vehicle, passengers, and cargo. The suspension system should provide enough ground clearance for uneven roads and off-road driving. A robust suspension system will also improve the stability of the vehicle during cornering and sudden manoeuvres.

Powertrain:

The power train of an electric van includes the electric motor, inverter, and gearbox. The electric motor must provide enough power and torque to move the vehicle and its occupants. A 1500kg electric 14-seater van requires a high-capacity motor, typically ranging from 10 kW to 100 kW, depending on the desired performance. The inverter converts DC power from the battery to AC power for the motor, while the gearbox controls the speed and torque of the motor. The power train must be designed to be energy efficient and reliable.

Battery:

The battery is the most critical component of an electric vehicle, providing power to the motor and all other electrical systems. A 1500kg electric 14-seater van requires a high-capacity battery with a range of 80 - 150 km. The battery should be designed to provide enough power to the motor, inverter, and other electrical systems. The battery should also be lightweight, durable, and have a long lifespan and swappable . Lithium-ion batteries are the most commonly used battery technology for electric vehicles.

Electric Motor:

The electric motor is the heart of an electric vehicle, providing power and torque to the wheels. A 1500kg electric 14-seater van requires a high-capacity motor that can deliver enough torque to move the vehicle and its passengers. The motor must be designed to be energy efficient, lightweight, and durable. The motor should also be designed to work with the battery and inverter for optimal performance.

Durability:

The durability of a vehicle is critical, ensuring that it can withstand the rigours of everyday use and harsh driving conditions. For a 1500kg electric 14-seater van, the durability design should consider factors such as corrosion resistance, wear and tear, and extreme temperature conditions. The mechanical parts should be designed to withstand the weight of the vehicle, passengers, and cargo, without compromising on safety or performance.

Stability:

The chassis and suspension should be designed to provide a stable ride, while the power train and battery should be positioned to ensure optimal weight distribution and balance. In addition, the design of the steering system should be optimised for precision and responsiveness to enhance the vehicle's stability and handling characteristics. Overall, a comprehensive stability design is crucial to ensure the safe operation of the electric 14-seater van, and should be a top priority for any vehicle designer or manufacturer.

III- Prototyping: 

The third stage was the prototyping stage, where the team of engineers and technicians built the first prototype of the vehicle. The prototyping stage for designing the 14-seater electric van involved several essential stages, including:Concept Development, Sketching and Drawing: Computer-Aided Design (CAD), 3D Printing, Fiberglass Molding to create the van's body shape, including the exterior shell, roof,Interior Components including the seats, dashboard, and other features.Exterior Components: including the lights, bumpers, and windshields, Assembly: including the interior and exterior components, electrical and mechanical systems, and batteries.

Refining: Based on the test results, necessary refinements are made to the design, and the prototyping process is repeated until a final design is achieved.

IV- Testing and Validation: 

The fourth stage is the testing and validation stage, where the prototype will be put through rigorous testing to ensure that it meets the design requirements. This stage involves testing the vehicle's performance, safety, and durability. The team will collect data from the tests and use it to make improvements to the design.

V- Manufacturing: 

The final stage is the manufacturing stage, where the team will begin production of the vehicle.The manufacturing process of the electric van involves several stages, including:

Design for Manufacturability (DFM): 

The DFM process ensures that the van's design is optimised for the manufacturing process, making it easier to produce and assemble.

Feasibility Study: A feasibility study is conducted to determine the viability of the manufacturing process, including the availability of resources, costs, and technical capabilities.

Production Line Design: 

The production line design involves planning and designing the manufacturing process, including the layout, workflow, and equipment required.

Material Procurement:

Overall, finding outsources for manufacturing components and parts for i602 involves a thorough assessment of potential suppliers' capabilities, a detailed RFP, and effective negotiation and contract management. It is crucial to select reliable and competent suppliers to ensure the production of high-quality components and parts.

Assembly: 

The assembly process involves assembling the various components of the van, including the chassis, interior and exterior parts of the body, electrical and mechanical systems, and battery packs.

Quality Control:

Quality control measures are put in place to ensure that the manufactured vans meet the required quality standards.

Testing: 

The manufactured vans are subjected to various tests, including performance, safety, and durability tests.

Designing the production line involves optimising the manufacturing process to ensure efficiency and reduce production costs. This involves selecting appropriate equipment, developing a suitable layout, and establishing workflow processes. The production line design also considers factors such as the required production capacity and the production lead time.