At a practical level, one of the project’s concrete tasks is the planning and construction of two electric vehicles in collaboration between the Jokilaaksojen Koulutuskuntayhtymä JEDU and the Future Manufacturing Technologies (FMT) research group at the University of Oulu Kerttu Saalasti Institute. FMT is responsible for vehicle design and coordinating the manufacturing, while the construction is carried out by JEDU’s Haapavesi and Nivala units.
The concept chosen for the electric vehicles, following an ideation process, is a rear-wheel drive, tubular frame car with a fiberglass body. The electrical systems are not built from scratch; instead, existing solutions are utilized. The project has acquired two damaged Nissan Leaf electric vehicles, from which the electrical systems are extracted and transferred to the new cars. As a result, the original front-wheel-drive Leaf is transformed into a rear-wheel-drive sports car; the selected body model for the build is the Alpine A110.
The design and fabrication of the tubular frame utilize the best available methods and materials. The frame tubes are made from SSAB’s Docol Tube R8, a steel optimized for bending and welding, commonly used in roll cages and drag racing cars. All frame tube parts, including their end cuts, are designed using 3D software. Based on the models, the tubes are cut with a tube laser and bent using CNC tube bending machines, ensuring precise, ready-to-assemble parts.
3D scanning has also been employed to assist in frame design. In the first phase, the front frame structure, subframes, and wheel suspension of the disassembled cars were scanned. Based on the scans, the chassis and steering geometries were modeled digitally, and the new frame was designed to be compatible with the Leaf’s components. The scans revealed, among other things, that the original Nissan shock absorbers could not be used in the new vehicle. In the second phase, the Leaf’s motor and other auxiliary components that will be transferred to the new car were scanned.
One of the major technical challenges in the project is the size of the battery pack required by the electric vehicle. The original 24 kWh Leaf battery is located under the floor beneath the driver and passenger seats. However, this setup won’t fit in the new vehicle, as the Alpine A110’s sports car body is very low. Therefore, the battery must be dismantled down to individual modules and redistributed into two battery units located in the front and rear of the car.
The frame construction of the vehicles is now underway. Jig tables have been designed and built to ensure the frame is welded accurately to specifications. The main frame tubes must be positioned with precision to ensure that the pre-cut and bent tube parts fit exactly into place.
The next steps for the project include finalizing the fit of all technical components into the designed tubular frame and designing suitable enclosures for the new battery units. The fiberglass car bodies have been ordered and are expected to arrive during the summer. Once they arrive, they will be 3D scanned to support precise planning of their attachment to the frame.
Perhaps the most valuable aspect of the project is the opportunity it provides to develop and cultivate regional expertise in electric vehicle technologies. In addition to the project staff, a significant number of JEDU students are involved, gaining hands-on experience with EV technologies in a real-world learning environment.
Author: Terho Iso-Junno, M.Sc. (Tech), Project Manager, University of Oulu Kerttu Saalasti Institute, Future Manufacturing Technologies (FMT) Research Group
Photo: Terho Iso-Junno
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