ALSTOM Support HM-V1

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The support structure employs sheet metal fabrication exclusively, eliminating extra cutting or manufacturing processes. Precision laser cutting ensures parts fit together perfectly for welding at strategic locations. FEA studies will determine exact welding requirements and weld positions. The design is optimized to provide adequate support for loads, with reaction forces accurately calculated via virtual prototyping software. Combined battery box and peso loads yield the highest stresses; other supports experience less stress. The average safety factor in the beam surpasses 6, except near fixation points. Gusset plates strengthened areas to enhance stiffness and reduce deformation. S275JR steel is the baseline material, with potential for weight savings using alternative materials. The support set weighs approximately 151 kg, representing a 47% reduction in weight compared to previous designs. By utilizing the same support member across all five supports, separate brackets are made for battery box mounts, reducing unnecessary manufacturing costs. Estimated manufacturing cost for the support set (5 units) is €1050. FEA studies revealed software crashes when attempting to save the entire assembly with provided battery and converter units; thus, individual mounts were saved, and a "design space reference box" showcased the project's confines.