We Design the Future of Transportation

ADVANCED LIGHT-WEIGHT BATTERY SYSTEMS OPTIMIZED FOR FAST CHARGING, SAFETY, AND SECOND-LIFE APPLICATIONS

The ALBATROSS project, was undertaken by Yeşilova Holding as the coordinator and in which a total of 21 partners from 10 different countries took charge; it is a battery carrier development project that addresses the needs of the European Electric and Hybrid-Electric passenger car market, eliminates range concerns, reduces costs, and aims to reduce long-term reliability and charging time problems.​

Within the scope of the work to be done in the ALBATROSS project, the BMW i3 passenger car will be used; with the new technologies to be developed, it is aimed to increase the driving range to 480 km and to reduce the battery charging time by 25%. As part of a flexible advanced battery management system; Cloud management systems will be integrated for remote maintenance and troubleshooting, ensuring on-vehicle security with advanced detection and control.​

ADVANCED LIGHT MATERIALS FOR SUSTAINABLE ELECTRICAL VEHICLES BY INTEGRATION OF ECO-DESIGN AND CIRCULAR ECONOMY STRATEGIES​

LEVIS is a project in which Yeşilova Holding is a partner and a total of 13 partners from 7 different countries are involved. Within the scope of the project, it is aimed to develop specified vehicle components (suspension control arm, battery box and glove box crossmember) by utilizing multi-material solutions based on metal-integrated fiber-reinforced thermoplastic composites in order to develop cost-effective and sustainable lightweight components for electric vehicles.​

Yeşilova Holding will carry out the battery box design and manufacturing studies using aluminum and new generation composite materials in the LEVIS project; will carry out the validation studies of the product with virtual and physical validation tests.

Development of Lightweight Battery Carriers for EV Energy Units

The LightBEE project was undertaken by Yeşilova Holding as the coordinator and a total of 8 partners from 3 different countries took part; For the Tofaş Doblo transformation vehicle, it is aimed to develop a new generation battery carrier that overcomes the technical limitations encountered during the battery box design and production stages, and meets critical characteristics such as lightness, mechanical strength and thermal conductivity by using a combination of aluminum and composite materials.​

In the battery box specially designed for Doblo’s transformation vehicle, 6xxx – 7xxx series aluminum alloys are used together. Friction Stir Welding (FSW) and Friction Stir Spot Welding (FSSW), which are innovative welding methods, are used to join extruded aluminum profiles.​

The torpedo crossmember produced by Ford OTOSAN using 100% steel material, and for the first time in Turkey, Yeşilova Holding developed a domestic 100% aluminum torpedo crossmember for an OEM. This product, which is at the prototype level, was designed together with Ford OTOSAN and verified by structural analysis.​

Currently, the number of 25-30 sub-components in the torpedo sleeper, which is produced using steel material, has been reduced to the level of 15-20 thanks to the injection molding and extrusion aluminum part designs.​

As a result of the studies carried out within the scope of the project, 43.12% weight reduction was achieved in the product by converting the steel product into aluminum.​

Yeşilova Holding developed the first domestic aluminum engine cradle for M2 class electric vehicles produced by e.GO Mobile, which meets the expectations of lightness and functionality, as well as ensuring full compliance with product regulations. The sub-components of the relevant engine cradle have been designed using topology optimization; The final product has been verified by structural analysis.​

A weight gain of 43.76% in the total weight of the engine cradle and 34.4% in the number of parts was achieved. ​ ​

With the engine cradle design and product verification competence obtained with the related project, the success of being an FSS (Full-Service Supplier) has been achieved for AWD and BEV products, which are the electric and non-electric versions of the Ford V710 project.​

Within the scope of the project, a magnesium crash bumper for light commercial/passenger vehicles was developed by Yeşilova Holding. Magnesium extrusion was tried and successfully produced for the first time in our country. ​ ​

Specific to magnesium alloys; mold design, product design, extrusion process analysis, mold production, extrusion process, heat treatment and welding competence.