VEHICLE STRENGTH BEYOND GOOD LOOKS

The WOLF Truck Withstands Over 16,000lbs of Stress, Performing Beyond Good Looks

"Alpha is efficiently achieving high-quality vehicle construction, effectively advancing preproduction through straightforward engineering solutions, establishing strong fundamentals. Furthermore, by simplifying our technology for scalability, our solutions boost the development of Alpha’s entire EV lineup." - Alpha Motor Corporation

In a previous report, we outlined Alpha's commercialization process, streamlining high product quality across a diverse range of electric vehicles. This process speaks to Alpha’s unique application of virtual validation, where advanced simulation tools, including Finite Element Analysis (FEA), analyze rigidity to assess how materials and designs withstand dynamic forces. Von Mises stress identifies potential areas of concern for yielding or failure, ensuring a comprehensive evaluation of structural worthiness before the development of physical prototypes.

Below are the FEA results of stress testing a demo version of the WOLF vehicle structure. The results reveal that the frame of the WOLF successfully withstands 16,000lbs. of pressure without any critical failure. This is nearly four times the projected weight of the WOLF electric truck.

16,000LBS. on Cabin, 1,000lbs. on Front - Von Mises Overview

In the context of FEA, Von Mises stress is a scalar value employed to represent the combination of principal stresses at a specific point within a material. It is derived from the three principal stresses (normal stresses) and proves particularly useful for evaluating the potential yielding or failure of a material under complex loading conditions.

This stress measure is often employed in FEA to predict material failure or yielding since it accounts for all three principal stresses and provides a single scalar value for comparison with material yield criteria. It is particularly useful in situations where different stress components act simultaneously, and a unified measure of stress is required for assessing structural integrity.

In the realm of vehicle safety and structural analysis, the term "crash" generally refers to a collision or impact, and it involves complex dynamic forces that can affect the structural integrity of a vehicle. Below is a breakdown of key terms and concepts:

1. Crash:

   • A crash involves a sudden impact between two or more objects, such as vehicles in a collision.

   • Crashes can result from various factors, including accidents, collisions, or deliberate testing in controlled environments.

2. Stress and Von Mises Stress:

   • Stress refers to the internal resistance of a material to deformation caused by applied forces. In a crash scenario, a vehicle's structure experiences dynamic and varying forces.

   • Von Mises stress, as discussed earlier, is a scalar value derived from the principal stresses and is often used in Finite Element Analysis (FEA) to assess potential yielding or failure of materials under complex loading conditions, such as those occurring during a crash.

3. Pressure in a Crash:

   • Pressure can be a component of the overall stress experienced by a vehicle's structure during a crash. For example, the force exerted on the front of a vehicle during a collision can result in pressure being applied to the impacted area.

4. Dynamic Loading:

   • Unlike static loading conditions, where forces are constant, crashes involve dynamic loading with rapidly changing forces and impacts. This dynamic nature makes crash analysis more complex, requiring consideration of factors such as vehicle speed, angles of impact, and material properties.

The Federal Motor Vehicle Safety Standards (FMVSS) include various regulations and requirements to ensure the safety and structural integrity of vehicles. These standards cover a range of aspects related to crashworthiness, occupant protection, and overall vehicle performance. Here are some structural integrity measures and considerations required by FMVSS:

1. Frontal Impact (FMVSS 208):

   • FMVSS 208 sets standards for occupant protection in frontal impacts. It includes requirements for restraint systems (e.g., airbags and seat belts) and crashworthiness of the vehicle's front structure.

2. Side Impact (FMVSS 214):

   • FMVSS 214 focuses on protecting occupants in side-impact collisions. This standard includes requirements for side-impact door beams, energy-absorbing materials, and the structural integrity of the vehicle's side.

3. Roof Crush Resistance (FMVSS 216):

   • FMVSS 216 addresses roof strength to minimize the risk of injury in rollover crashes. The standard sets requirements for the amount of force a roof must withstand during a static test to ensure it can support the vehicle's weight.

4. Rear Impact (FMVSS 301):

   • FMVSS 301 establishes requirements for fuel system integrity in rear-end collisions. It aims to minimize the risk of post-collision fuel leaks and fires.

     • For electric vehicles, where there is no traditional liquid fuel system, compliance with FMVSS 301 is approached differently:

     • Battery Integrity: Instead of focusing on a fuel system, electric vehicles must ensure the integrity of their high-voltage battery systems. The design and placement of the battery pack need to minimize the risk of damage and subsequent fire hazard in the event of a rear impact.

     • Crash Testing: Electric vehicles undergo crash tests to assess the vehicle's response to rear-end collisions, ensuring that the battery and other components maintain their integrity. This may involve structural design considerations to protect the battery enclosure and components.

     • Safety Standards: While FMVSS 301 is specific to fuel system integrity, electric vehicles must still comply with other safety standards related to occupant protection, crashworthiness, and overall vehicle safety.

     • Type Approval: Electric vehicles, like their internal combustion engine counterparts, often go through type approval processes to ensure compliance with various safety standards, including FMVSS 301.

1. Dynamic Rollover (FMVSS 126):

   • FMVSS 126 addresses Electronic Stability Control (ESC) systems, which help prevent skidding and loss of control. This contributes to overall vehicle stability and reduces the likelihood of rollover accidents.

2. Bumper Standards (FMVSS 581):

   • FMVSS 581 sets standards for bumper strength and design to protect vehicle occupants and pedestrians in low-speed collisions.

3. Door Locks and Retention (FMVSS 206):

   • FMVSS 206 establishes requirements for door locks and door retention to prevent doors from opening during crashes.

4. Child Restraint Anchorage Systems (FMVSS 225):

   • FMVSS 225 sets standards for anchorage systems to secure child restraint systems within the vehicle.

5. Glazing Materials (FMVSS 205):

   • FMVSS 205 establishes standards for automotive glazing materials to ensure they provide adequate visibility and do not shatter dangerously during a collision.

Alpha is actively advancing  vehicle compliance, including those related to structural integrity and safety in preproduction. This is possible due to Alpha's cost-efficient validation of crucial engineering milestones through both virtual validation including tools such as FEA and physical testing, demonstrating our operational efficiency and automotive expertise. The successful testing of prototypes, including a functional driving prototype, allows Alpha to apply validated engineering solutions across its vehicle lineup. This advancement not only furthers vehicle development but also efficiently expands Alpha's consumer base.