First vehicle Platform project on 2001
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The document provides details on benchmarking activities conducted to assist in developing targets for a new vehicle body configuration called Project SP2. Static benchmarking was performed on various vehicles to analyze their body types, including the Kia Cerato, Renault Mégane II, Renault Logan, Nissan Teana, Nissan Qashqai, and Peugeot 206. This provided advantages and disadvantages of each component and information to define characteristics for SP2's market position. Scenario 1 is proposed which uses the Renault Logan platform as the base, modifying it according to different body types while maintaining common front ends and production processes to reduce time, cost and investment.
First vehicle Platform project on 2001
- 3. • to provide resting space for customers, • to serve as a bridge between front and rear subsystems, • to provide a passageway for powertrain and exhaust components, • to protect vehicle against water intrusion, • to connect major load-carrying members - rails, cross members, rockers, etc., • to enable seats, restraints, etc. • to be attached to the body, • to provide roomy interior and rest space for customer's legs, • to prevent heat and noise intrusion from the engine into the passenger compartment, • to provide attachments to the instrument panel and steering subsystem, • to provide attachments to the plenum, • to protect customers in the event of roof crush, • to directly protect customers from rain, snow, sunshine, and other hazards, • to improve windnoise, vibration and harshness characteristics, • to connect the pillars to the lower half of the vehicle, • to provide attachment for seat belts, • To connect the roof, front structure, underbody and rear end • to form the complete body structure, • to provide attachments for the doors and windows, • to add several reinforcements to improve upon the rigidity of the body system, • to provide surfaces (interior and exterior) for trim and ornamentation, • to provide attachments for rear seats, • to improve sound quality (attachment for speakers), • to attach to rear bumper, • To provide storage space (cargo/spare tire), • to protect customers in rear impact, • to provide attachments for lights and ornamentation, • to provide towing and coupling attachments, • to support the engine and the subframe (rails), front suspension and steering gear, • to support the radiator, • to provide housing for front wheels, • to provide attachment for steering subsystems and cowl, • to support the bumper subsystem, • to provide protection in frontal crash, • to provide attachment for engine compartment components, • to support the battery/battery tray. 1.1 Body functions : The primary functions of the Underbody - Body Structure are:
- 5. 2.1 Benchmarking Body : To ensure efficient development work on vehicle body configurations from the point of view of; • static, • structural dynamics • and optimum weight, The definition targets as input data for the development process is required at a very early stage. These targets are obtained by continuously converting what are often only subjective demands on the vehicle body into quantitative targets. Benchmarking allows the characteristic data to be defined for a new product and therefore assists in determining its market position . Benchmarking activities were conducted in two stages to assists the process 1. Static benchmarking 2. Dynamic benchmarking (not used within the BIW process hence not mentioned within the report)
- 6. 2.2 Static Benchmarking: Benchmarking activities were conducted using vehicles or information which were at our disposal or were easily available through the company A network company A Kia-Cerato PARS KHODRO Mégane II Renault Logan Nissan Teana Nissan Qashqai Others (data available) Peugeot 206
- 7. Vehicle Picture Type Advantages Disadvantages Kia- Cerato Front Frame assy •Ease of manufacturing •Ideal shape for controlling deformation •Integrated bracket to support powertrain sub- frame •Weight – excessive •Material - unknown Kia- Cerato Firewall •Ease of manufacturing •Irregular shape – complex •Weak structure compared with other benchmarked BIW’s e.g. lack of cross members Kia- Cerato Panel floor •Ease of manufacturing •One piece stamping – cannot be used for other variants e.g. pick-up •Tunnel section to narrow e.g. cannot pass exhaust & prop-shaft together Kia- Cerato Rear cross- member •Ease of manufacturing •Simple design •Initial assumptions – good for rear impact i.e. controlled deformation
- 8. Vehicle Picture Type Advantages Disadvantages Mégane II Front Frame assy •Powertrain packaging environment & space •Up to date technology & material deployed •Minimum sub- assemblies •Ease of manufacturing Mégane II Firewall •One piece x-member •Brackets controlling longitudinal •Ease of manufacturing •Up to date technology & material deployed Mégane II Panel floor •Ease of manufacturing •Up to date technology & material deployed •3 piece floor panel •HSS used for seat brackets Mégane II Rear crossmember •Composite spare wheel carrier – light weight •Rear beams – strong
- 9. Vehicle Picture Type Advantages Disadvantages Renault Logan Front Frame assy •Powertrain packaging environment & space •Minimum sub- assemblies •Ease of manufacturing •Old Technology & material deployed •Front longitudinal not ideal for frontal impact i.e. deformation can not be controlled Renault Logan Firewall •One piece x-member •Brackets controlling longitudinal •Ease of manufacturing Renault Logan Panel floor •Ease of manufacturing •3 piece floor panel Renault Logan Rear crossmember •Rear beams – simple •Rear impact capabilities - unknown
- 10. Vehicle Picture Type Advantages Disadvantages Nissan Teana Front Frame assy •Powertrain packaging environment & space •Up to date technology & material (AHSS) deployed •Design – fit for today's requirements • many sub- assemblies •Manufacturing – complicated Nissan Teana Firewall •One piece x-member •Brackets controlling longitudinal • Manufacturing – complicated Nissan Teana Panel floor •Ease of manufacturing •Up to date technology & material deployed •3 piece floor panel •HSS used for seat brackets Nissan Teana Rear crossmember •Simple & strong rear end •HSS material used for the main beams •Ease of manufacturing
- 11. Vehicle Picture Type Advantages Disadvantages Nissan Qashqai Front Frame assy •Powertrain packaging environment & space •Up to date technology & material (AHSS) deployed •Longitudinal shape – ideal for crash control •Simple sub-frame mounting design Nissan Qashqai Firewall •One piece x-member •Brackets controlling longitudinal •Up to date technology & material (HSS) deployed •Ease of manufacturing Nissan Qashqai Panel floor •Ease of manufacturing •Up to date technology & material deployed •3 piece floor panel •AHSS used for seat brackets Nissan Qashqai Rear crossmember •Simple & strong rear end •HSS material used for the main beams •Ease of manufacturing •Many sub assemblies
- 12. Vehicle Picture Type Advantages Disadvantages Peugeot 206 Front Frame assy •Powertrain packaging environment & space •Up to date technology & material (HSS in specific areas) deployed •Longitudinal shape – ideal for crash control Peugeot 206 Firewall •One piece x-member •Brackets controlling longitudinal •Ease of manufacturing Peugeot 206 Panel floor •Ease of manufacturing •Up to date technology & material deployed •2 piece floor panel •Longitudinal beams not used Peugeot 206 Rear crossmember •Simple & strong rear end •Ease of manufacturing
- 14. Attribute Comments (based on target vehicle-Logan) 1. Safety •Body Deformation & Occupant Injuries Improve on the current front structure - improve shape, sections & technology •Design Of Interiors & Safety Equipment New materials proposed 2. Security •Valuable Devices introduce small deflector panels •Theft of Vehicle Contents spare wheel inside trunk (all except), (pick-up) behind passenger seat, (MPV) under floor (theft proof cage) 3. Packaging and Ergonomics •All related requirements Concepts completed with dictated packaging dimensions 4. Thermal & Aerodynamics – Not related 5. Vehicle dynamics •Handling provide a stiff platform to ensure adequate handling 6. Protecting Environment •Emission Reduce BIW weight •Recyclability Usage of recyclable material
- 15. Attribute Comments (based on target vehicle-Logan) 7. Performance/ Fuel economy •Performance & Drivability Reduce BIW weight •Economy Reduce BIW weight •Energy Utilization Petrol only (to date) •Transmission packaging space provided 8. NVH •NVH ensure BIW NVH sensitivity is sufficient 9. Electrical/Electronics •Facilities Provide space for modules 10. Interior climate comfort •ventilation, heating and cooling HVAC module packaged 11. Weight •Mass & Dimension Reduce BIW weight
- 16. Attribute Comments (based on target vehicle-Logan) 12. Product/ Process Design •Product/ Process Design (platform) High commonality considered 13.Customer Life cycle •Serviceability /Reparability Same practices as target vehicle used •Durability / Reliability sufficient torsion & bending stiffness's identified to ensure durability of the BIW. •Corrosion Coated material used where possible 14. Electrical/Electronics •Facilities Provide space for modules 15. Interior climate comfort •ventilation, heating and cooling HVAC module packaged 16. Weight •Mass & Dimension Reduce BIW weight
- 18. 4.1 Ideal strategies for new platform solution: • Create a new platform by modifying it according to type maintaining common front end and front floor for all type. • Usage of Logan & Other company A product parts bin . • Usage of current production facilities/Process (Updating where required). Vehicle Class Comments Pride B Not in the same class of PF2 but parts bin may be used Xantia D Phased out - CKD from PSA Rio C Not in the same class of PF2 - CKD from KIA Tiba C Not in the same class of PF2 but parts bin may be used Megan D CKD from Renault Turkey Logan C PROPRIETARY design by Renault
- 19. 4.2 Scenario 1 Using the base from a existing model & updating it to suit company A’s requirements Ideal Potential – Logan Using parts and production facilities of Logan & Creating a new platform by modifying it according to body type maintaining main features: •New style themes for PF2 1-Sedan 2-Hatch back 3-SUV 4-MPV 5-Pickup •Common front end for all types •Modifying floor area for specific body type •Production facilities & processes available
- 20. Advantages 1. ‘C’ Class 2. Proved out technology (i.e. crash ENCAP 3 – pre-2009) 3. High commonality with Logan 4. Usage of existing parts bin 5. Time & cost during development 6. Low investment Disadvantages 1. Renault/Nissan may not allow this platform to be used i.e. SR project still under review (by owners of platform) after 3 years of negotiation. 2. No independency for company A. 3. Lack of information regarding commonality (refer to Next Slide) 4. May not be suitable for variable body type as proposed by PF2 5. Logan has had many updates during its time at Company. The platform (vehicle) currently produced in IRAN the design is at least a year behind the ones produced in other area such as Russia, India.. Owners of Logan changes parts & design at will – updates unknown 6. Supplier may not be local or localization may not be possible Scenario 1 cont.
- 21. From previous slide disadvantages Item 3. Lack of information regarding commonality Scenario 1 cont. Vehicle Wheel Base Length Ground clearance SEDAN 2630 4250 155 H/Back 2588 4020 N/A MPV 2905 4450 160 SUV 2673 4315 205 Pickup 2905 4496 N/A
- 22. 4.3 Scenario 2 New Platform to suit company A’s future requirements • Platform • common modular systems and components • maximise structural commonality • maintain power-train mounting points • maintain rear suspension mounting points •Suitable for all type of variation 1-Sedan 2-Hatch back 3-SUV 4-MPV 5-Pickup • company A parts bin can be used where possible . • Production facilities/Process modified to suit, increasing local supplier potential .
- 23. Advantages 1. Deploying new trends & technologies 2. Idea comprise between development and cost . 3. company A owned platform - No royalties 4. Commonality through out the variable body type (refer to next slide) 5. New knowledge acquired - How to design and development a platform 6. Facelifts or model year changes possible when needed . Disadvantages 1. Investment for development & manufacturing required 2. New technologies to be acquired Scenario 2 cont.
- 24. company A Owned Platform New design (max usage of company A’s Parts Bin) Proceeding forward using the benchmarking data gathered (advantages & disadvantages) Vehicle Wheel Base Length Ground clearance SEDAN 2650 4595 180 H/Back 2650 4345 180 MPV 2650 4435 180 SUV 2650 4435 280 Pickup 2900 4625 280
- 25. Way Forward From the previous slides the 2 scenarios presented, both have advantages & disadvantages. With the knowledge gained it is obvious that the way forward for the company A group is to have an independently owned platform i.e. scenario 2 (linked closely to scenario 1 using base knowledge from Logan) From this point forwards all the discussion are based on a newly developed Platform
- 26. 5. Platform and first vehicle proposal &Configuration
- 27. 5.1 Structural concept: •Wants from Platform. •Primary concept. •BIW - Underbody concept layout. •Front rail & Eng. Compartment. •Panel dash Lwr assy. •Front floor assy. •Rear floor assy. Top View Bottom View
- 28. Wants from Platform. Top View Bottom View Front-suspension system Concept from Logan Corporate seating system (i.e. Megane/Rio) Rear-susp. system Concept from •FWD - Logan •4WD - Qashqai Safety requirements to meet (2015 -2020) Safety requirements to meet (2015 -2020) Safety requirements to meet (2015 -2020) Rear cargo space leader in its class Capable of packaging a variety of power-trains
- 29. Primary concept: •The fundamental tasks for PF2 body structures is that they meet the program targets: 1. Safety & Crashworthiness. 2. Lightweight design concept to contribute towards the reduction of; i. CO2-emission ii. Fuel consumption 3. Vehicle dimension to meet packaging requirements. 4. Commonality and modularity. 5. CNG packaging capability. 6. Utilization of existing parts (where/possible) company A’s Parts Bin. 7. Using new technologies during process (where possible – availability & cost) i. tailor welded blanks for optimum rail performance. 8. Body structure designed using benchmarked vehicles (Nissan C platform and Renault B0 platform)
- 30. Eng. Compartment & Front rails: • to support the engine and the subframe (rails), front suspension and steering gear, •to support the radiator, •to provide housing for front wheels, •to provide attachment for steering subsystems and cowl, •to support the bumper subsystem, •to provide protection in frontal crash, •to provide attachment for engine compartment components, •to support the battery/battery tray. Engine/suspension sub-frame attachment Bumper crash box/can Longitudinal front rails
- 31. Bumper beams: • Crash energy management system. • Energy absorption without foam (intrusion reduced) • Direct air flow to the heat exchangers (radiators etc..). • Choice of material (weight reduced) Bumper crash box/can
- 32. DASH LWR CROSS CTR DASH LWR CROSS MBR REINF DASH LWR PANEL DASH LWR ASSY : •To connect major load-carrying members - rails, cross members, rockers, etc. •To enable seats, restraints. •To provide roomy interior and rest space for customer's legs. •To prevent heat and noise intrusion from the engine into the passenger compartment. •to provide attachments to the instrument panel and steering subsystem. •To improve •torsion stiffness •Firewall intrusion criteria •To absorb & distribute loads from the suspension into the body structure.
- 33. FRONT SIDE MBR MBR ASSY SIDE CTR CROSS MBR ASSY FRONT FLOOR CTR FRONT FLOOR ASSY : •To improve •bending stiffness. •To transfer load from the front rail to Rear floor assy.
- 34. FLOOR ASSY MBR ASSY Bumper crash box/can CROSS MBR ASSY REAR FLOOR ASSY : •To provide storage space (cargo/spare tire). •To protect customers in rear impact. •To attach to rear bumper.
- 35. BIW concept layout: SECTION 1-1 SECTION 2-2 SECTION 3-3 SECTION 4-4 SECTION 5-5 SECTION 6-6 SECTION 7-7 SECTION 8-8 SECTION 9-9 SECTION 1-1 SECTION 2-2 SECTION 3-3 SECTION 3-3SECTION 4-4 SECTION 5-5 SECTION 6-6 SECTION 7-7 SECTION 8-8 SECTION 9-9
- 36. BIW concept layout: SECTION 11-11 SECTION 10-10 SECTION 10-10 SECTION 11-11 SECTION 12-12 SECTION 12-12 SECTION 13-13 SECTION 13-13 SECTION 14-14 SECTION 14-14 SECTION 15-15 SECTION 15-15
- 37. 5.2 Assembly concept : 5.2.1 All variants (other than Pick-up) Assembly level 1 Assembly level 2Assembly level 3 •Sedan. •Hatchback. •SUV. •MPV. •Pickup
- 38. Assembly level 1: Common on all except SUV Common on all
- 39. Assembly level 2: Common on all
- 40. Assembly level 3: Different on all models(same geometry, different length) Common on all
- 41. Assembly level 4 5.2.2 Pick-up only •Sedan. •Hatchback. •SUV. •MPV. •Pickup
- 42. 5.3 Material concept : •Material specifications. •Tailored Blanks. •Engine Compartment & Front rails concept. •Front floor concept. •Rear floor concept.
- 43. Automotive Steel Families: Family Quality AM offer Eu Norm Exemple of application Drawing DC01- DC07 ArcelorMittal 01-07 ArcelorMittal 51-57 EN10111 EN10130 EN10152 EN10327 Bodyside, roof, floor, hood panels, crossmembers High Strength steels IFHSS IF180 – IF300 EN10268 EN10292 EN10152 EN10149 Door, hood, decklid outer panels Members, crossmembers BH 180BH – 300BH Rephosphorized H220 – H300 Isotropic E220i – E260i HSLA CR HSLA 260 – 420 HR HSLA 320 -550 Advanced High strength steels Dual Phase Complex Phase TRIP Martensitic DP450 -1180 DP HY and HHE TRIP 690 – 780 MS1200 EN10336 prEN10338 A, B, C Pillar R/F Member R/F Bumper, door beams Rocker panel Press hardened steels 22MnB5 USIBOR 22MnB5 USIBOR1500AS A Pillar, member, bumper beam Composite steels Vibration damping structural Quietsteel smoosteel Dash panel, engine cover, oil pan
- 44. 5.3.1 : Scenario 1 : Current Logan utilizing the following materials: •6% high strength steel •94% mild steel <10% high strength steel in body structure EuroNCAP 3-star crash rating (old rating) Deformation in upper A-pillar and roof
- 45. Eng. Compartment & Front rails concept: HE450 Th:1.0 DC04 Th:0.7 DC04 Th:1.8 DC04 Th:2.0 DC04 Th:1.0 DC04 Th:0.7 DC04 Th:1.0 DC04 Th:0.7 DC04 Th:0.7 DC04 Th:1.4 DC04 Th:2.5 DC04 Th:0.7 DC04 Th:0.7 DC04 Th:1.0 DC04 Th:1.0 DC04 Th:1.2 DC04 Th:0.7 DC04 Th:2.0 HE450 Rear Th:2.0 HE450 Front Th:1.7 DC04 Th:1.5 DC04 Th:2.0 DC04 Th:2.0 DC04 Th:2.0 Th:1.0 DC04 Th:1.2 Refer to slide 45 – table of materials
- 46. Front floor concept : DC04 Th:1.0 DC04 Th:1.5 DC04 Th:1.5 DC04 Th:1.5 DC04 Th:1.5 DC04 Th:1.5 DC04 Th:1.2 Refer to slide 45 – table of materials
- 47. Rear floor concept : DC04 Th:1.0 DC04 Th:0.7 DC04 Th:1.5 DC04 Th:1.5 DC04 Th:1.0 DC04 Th:1.7 DC04 Th:2.0 DC04 Th:1.6 DC04 Th:1.0 DC04 Th:1.6 DC04 Th:1.7 DC04 Th:0.7 DC04 Th:0.7 DC04 Th:0.7 DC04 Th:2.0 DC04 Th:1.0 DC04 Th:2.0 DC04 Th:0.7 DC04 Th:2.0 Th:1.0 Refer to slide 45 – table of materials
- 48. 5.3.2: Scenario 2 : Advanced steels used in constructing Body-in-White >70% high strength steel in body structure EuroNCAP 5-star crash rating (new rating) AHSS HSS To achieve the ratings set by PF2 the following example defines the direction to be adopted: Using latest available materials as suggested/available by the supplier (POSCO) No deformation of passenger cell
- 49. Eng. Compartment & Front rails concept : DP590 Th:1.0 HSLA-250 Th:0.7 DP600 Th:1.8 DP500 Th:2.0 DP590 Th:1.0 HSLA320 Th:0.7 BH300 Th:1.0 BH210 Th:0.7 BH210 Th:0.7 DP590 Th:1.4 HSLA320 Th:2.5 BH500 Th:0.7 BH210 Th:0.7 DP500 Th:1.0 DP500 Th:1.0 HSLA320 Th:1.2 DP500 Th:0.7 HSLA550 Th:2.0 DP600 Rear Th:2.0 DP600 Front Th:1.7 DP600 Rear Th:2.0 DP600 Front Th:1.7 DP500 Th:1.5 DP500 Th:2.0 DP-600 Th:2.0 DP600 Th:2.0 Th:1.0 DP590 Th:1.2 Refer to slide 45 – table of materials
- 50. Front floor concept : DP600 Th:1.0 DP590 Th:1.5 DP500 Th:1.5 DP- 450 Th:1.5 DP590 Th:1.5 DP590 Th:1.5 DP500 Th:1.2 Refer to slide 45 – table of materials
- 51. Rear floor concept : DC04 Th:1.0 DC04 Th:0.7 HSLA550 Th:1.5 DP500 Th:1.5 DP500 Th:1.0 DP500 Th:1.7 DP500 Th:2.0 DP500 Th:1.6 HSLA320 Th:1.0 DP590 Th:1.6 DP500 Th:1.7 BH210 Th:0.7 BH210 Th:0.7 DP590 Th:0.7 DP500 Th:2.0 DP500 Th:1.0 DP500 Th:2.0 DC04 Th:0.7 DP600 Th:2.0 Th:1.0 Refer to slide 45 – table of materials
- 52. Tailored Blanks : •Advantages of Tailored Blanks: Weight Parts Stability Overlap joints Reduction •Material •Mass •Transported Reduction •Tool costs •Press shop costs •Assembly costs •Material costs •Logistic costs Improvement •Fatigue values •Crash behaviour Reduction •overlap joints Improvement •corrosion
- 53. Tailored Blanks cont. •Concepts for PF2: Laser weld seam Laser weld seam Laser weld seam
- 54. 5.7 Recommendation for joining technologies : •Joining Crimping seam Riveted joints Laser- welded seam Resistance spot welding Welding bolts MAG welded seam Projection welded joints
- 55. FARSHID HESAMI Email Address : farshidhesami@gmail.com BIW EXPERT ENGINEER https://www.linkedin.com/in/farshid-hesami-33a09529/ Cellphone : +989123387563
Editor's Notes
- #43: Company members of the international iron and steel institute.