ALSTOM Support HM-V3

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This simple yet robust support features a main body consisting of a single bent sheet metal panel with welded-in supports, making it easy to manufacture and strong. Crafted from 8mm steel, the design can easily bend into shape and becomes even stronger when joined with support braces. Each set weighs approximately 178.5 kg, offering a 37% weight reduction. The key advantage lies in its cost-effective manufacturing process using high-tolerance sheet metal laser techniques for consistent accuracy. Estimated production costs are around €950 per set. A preliminary stress analysis indicates the design can handle forces with ample safety margins, drawing strength from its 8mm thick steel components. The worst-case scenario involves supporting a battery box and static converter, with forces of 840 N downwards on each connection and 2,200 N downwards on the converter. These values were used in the FEA structural analysis, which resulted in an average safety factor of 1.6. It is crucial to consider welds in areas that reduce stress concentrations during the FEA process, not just the sheet metal body.