Structural design: Layout determines the structure
The engine and gearbox of fuel vehicles have a large volume, concentrated in the front, and the front of the white body needs to have a complex frame. Like traditional fuel powered cars, the sturdy longitudinal and transverse beams form a sturdy engine compartment, carrying the power system and meeting the safety requirements for engine sinking during collisions, just like building a “fortress” for the engine.
The electric vehicle battery pack is laid flat on the bottom of the car, and the motor is compact and flexible. Its white body front does not require a large amount of space reserved for the engine, with a simple structure and an additional front trunk to increase storage space. At the same time, the low-level layout of the battery pack reduces the center of gravity and improves handling stability.
In terms of collision safety, fuel vehicles are designed to prevent damage to the engine and fuel system, as well as the collapse of the engine compartment, energy absorption, and firewall strength; Electric vehicles focus on protecting the battery pack by installing high-strength protective beams and collision buffer zones.
Material application: Different from lightweight
Environmental protection and energy conservation promote the light-weighting of automobiles. Fuel vehicles reduce fuel consumption mainly by using high-strength steel, with some non critical parts made of aluminum alloy, such as the engine hood and doors of mid to high end cars.
Electric vehicles have a more urgent demand for lightweight due to their heavy batteries. Many electric vehicles use aluminum alloy materials extensively on their white bodies to reduce weight and improve range. Some high-end electric vehicles use carbon fiber composite materials, but the high cost has not been widely adopted. And the materials around the battery pack need to be high-strength, impact resistant, insulated, and corrosion-resistant, which is different from the requirements of fuel vehicle materials.
Manufacturing process: Adapted materials and design
Welding is the key to white body manufacturing. Fuel vehicles are mainly made of steel, commonly using resistance spot welding (low cost, high efficiency) and laser welding (for parts with high strength and appearance requirements).
Electric vehicles come in a variety of materials, and aluminum alloy welding requires special processes. Friction stir welding solves the problems of porosity and cracking in aluminum alloy welding, while laser brazing achieves high-quality connections.
Integrated die-casting is a new highlight in electric vehicle manufacturing. Some electric vehicles use a single die-casting process to form multiple components, reducing the number of parts and welding processes, improving efficiency, reducing weight, and enhancing rigidity. Fuel vehicles are difficult to apply on a large scale due to their complex structure.
New perspective on car purchasing: White body characteristics
Environmental protection and energy conservation promote the light-weighting of automobiles. Fuel vehicles reduce fuel consumption mainly by using high-strength steel, with some non critical parts made of aluminum alloy, such as the engine hood and doors of mid to high end cars.
Electric vehicles have a more urgent demand for lightweight due to their heavy batteries. Many electric vehicles use aluminum alloy materials extensively on their white bodies to reduce weight and improve range. Some high-end electric vehicles use carbon fiber composite materials, but the high cost has not been widely adopted. And the materials around the battery pack need to be high-strength, impact resistant, insulated, and corrosion-resistant, which is different from the requirements of fuel vehicle materials.