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Fisker Karma’s Aluminum Space Frame to Debut in Geneva

At the Geneva Motor Show next month, Fisker will be showing off the ‘advanced aluminum space frame’ that underpins the Karma plug-in hybrid and gives the car new levels of rigidity and strength.

Fisker Automotive’s engineering team designed the Karma’s space frame around the car’s unique Q-DRIVE series-hybrid powertrain, filing for multiple patents in the process. Q-DRIVE® consists of a 2.0-liter turbocharged ECOTEC engine/generator set, a lithium-ion battery pack from A123 Systems, and a rear-mounted 403hp traction motor assembly.

Though it forms the foundation of a large sedan the Karma space frame’s rigidity is exceptional even when compared to today’s sports cars. By utilizing 5,000- and 6,000- series aluminum alloys and a unique extrusion-intensive architecture, the Fisker engineering team achieved the best balance between weight and size.

A super-structural tunnel running down the car’s centerline acts as the Karma’s backbone. It not only houses the battery pack but acts as a torque tube connecting front and rear sections. For optimal strength the Karma’s space frame is joined with 79 meters of precision CMT MIG welds and 1,058 self-piercing rivets. Each technique is used independently only where necessary to ensure top quality and durability.

The result is an industry-leading space frame that provides a solid foundation for the Karma. Few cars match its statistics: Static torsional rigidity – the amount the space frame resists twisting forces when entering a ramp at an angle, for example – measures more than 33,000 Newton-meters per degree (Nm/deg). Static bending rigidity – the amount the space frame resists flexing forces as the car enters a ramp straight on, for example – measures more than 23,000 N/mm. Dynamic stiffness – the space frame’s resistance to resonant vibrations like those felt when driving over a sharp bump or rough road surfaces — is also world class.

Thanks to intelligent engineering solutions the Karma’s space frame also provides the utmost in occupant safety and exceeds global crash protection standards.

Front impact protection starts with a patent-pending, multi-cell tempered aluminum crush box that displaces high-impact energy away from passengers. Its unique design allows it to be easily replaced, reducing repair costs that could lower insurance premiums. Dual Phase 600-Series steel reinforced components in the doors and B- pillars provide substantial side impact protection. And the lithium-ion battery’s location in the center of the car puts it farthest from impact areas.

Valmet Automotive will assemble the space frames at its state-of-the-art facility in Uusikaupunki, Finland.[wzslider height=”400″ lightbox=”true”]

Feb 17, 2010Blagojce Krivevski
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Blagojce Krivevski

Blagojce Krivevski is physicist and green technology lover. Keep in touch with Blagojce through his email, web site, Twitter, Linkedin, Facebook and Google+.

February 17, 2010 Plug-in Hybridsfisker, fisker karma, geneva, geneva 2010, Geneva Motor Show, plug-in hybrid
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