2 Vehicle Development Process & Para Metrical Car Body Design_II

Platzhalter für Bild, Bild auf Titelfolie hinter das Logo einsetzen

Vehicle Body Engineering

Stechert, C. und Nehuis, F. ; Friday, October 01, 2010

1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering |

Agenda

1. Motivation

Vehicle history

Vehicle environment

2. Inauguration

Requirements (vehicle and car body)

Car concepts

3. Vehicle Development Process

Goal definitions

Costs

Materials

Manufacturing processes

4. Parametric Car Body Design

Tools and requirement

Virtual reality

5. Design Attributes

Package

Design

Light weight constructions

Noise vibration harshness

Modularisation

Safety


[Adam Opel AG]

1912: single production with flexible “model mix“


1927: implementation of assembly lines

[Adam Opel AG]


Vehicle production today - (fully) automated assembly line


Manufacturing costs by vehicle areas

[H. Lorenz: “Die Entwicklung des Energieverbrauches in den Werken”, Volkswagen AG, 2003]

Analysis of the shares of expenses for energy use

(approximate quantifying)

Fahrwerk

15%

Ausstattung

25%

Elektrik

10%

Karosserie inkl.

Lack

30%

Motor &

Getriebe

20%

Karosserie inkl. Lack

Fahrwerk

Motor+ Getriebe

Ausstattung

Elektrik

Verteilung des gesamten Primär-Energiebedarfes

WerkstoffBenzin Herstellung

Nutzungsphase

VW-Anteil

Entsorgung

Car body

including paint

30%

Underbody

15%

Electrical

equipment

10%

Equipment

components

25%

Engine &

Transmission

20%

VW shareGasoline production Material

Disposal

Utilisation phase


Body Production Process

[Th. Krusche, R. Koschorrek: "Konstruktionsmethodik und Karosseriekonzepte", Symposium anlässlich des 60. Geburtstages

von Prof. Dr.-Ing- H.-J. Franke, Braunschweig, 2004]

Manufacture

of

components

Body

construction

Cataphoretic

painting

sealing

assembly

Logistics-processes

The choice of construction and the material has an impact on the resulting

process chain

Purchase

Semi-finished

products

• Sheets

• Plates

• Profiles,

• …

• Stamping

• Pressing

• Deep drawing,

• …

• Mechanical

joining methods

• QS, …

• Thermal and

mechanical joining

methods, ...

• Sealing

• Painting

• …


Shell construction

Shell-monocoque construction

Frame- Monocoque construction

Shell- frame-monocoque construction

concept

Shell

construction

Monocoque

construction

Frame

mode of

construction

Scheme for optimized body production

[Th. Krusche, R. Koschorrek: "Konstruktionsmethodik und Karosseriekonzepte", Symposium anlässlich des 60. Geburtstages von Prof. Dr.-Ing- H.-J. Franke,

Braunschweig, 2004]

Technical criteria

Technological

criteria

Economic criteria

Logistics-processes

Manufacture of

componentes

Body

construction

Cataphoretic

painting, sealing Assembly

Purchase

Semi-finished

products

Technology catalogues

Pro

duction

Evalu

ation a

nd V

ariation 1st step

Selection of the general

construction

2nd step (a)

Intermediate substitution

2nd Step (b)

Quantifying of the component

production

3rd Step

Quantifying of the joining

tasks

4th step

Evaluation Process Steps

Optimized concept

for the supporting

structure

Main

com

ponents

ggf. Radhäuser innen

Kotflügel (r,l)Federbeinaufnahmen

Bodenwanne

Längsträger hinten

Hinter-wagen

Trennwand hinten

Bodenbleche

Trennwand vorn

Schweller (Längsträger) Dachfläche

Dachrahmen

Querträger hinten C-Säule außen

C-Säule

D-Säule

Sitzquerträger hinten B-Säule außen

B-Säule

Sitzquerträger vorn A-Säule außen

A-Säule

Querträger vorn

Fahrgast-zelle

Stoßfängerquerträger

Kotflügel (r,l)

Federbeinaufnahmen

Längsträger

Vorder-wagen

AußenhautTragstrukturBoden, Chassis

Radhausträger

Radhausträger

Without doors and hatches


Optimization of the process run - bodywork and painting

[H. Timm: „Kostenattraktiver Leichtbau“, Werkstofftag Volkswagen AG, Wolfsburg, 2003]

Rolling mill Pressing plant

Degreasing +

conversion Bodywork

Production of

the pressed

parts

Pre-treatment + cataphoretic painting

Separate

heat

treatment

Finish

Rolling mill Pressing plant

Production of

the pressed

parts

Bodywork Pre-treatment + cataphoretic painting

Paint-spray line

Manufacturing process Audi A8 (D2)

Manufacturing process Audi A8 (D3)

Space frame

and attaching

parts

Degreasing Cataphoretic

painting

Drying

20 min at

200°C

Degreasing Cataphoretic

painting

Drying

20 min at

>185°C

FinishSpace frame

and attaching

parts

1 Dry

lubrication

1 Conversion

2 Dry

lubrication

Paint-spray line

1

1

2


Process flow - space frame with plastic sheeting

[Volkswagen AG, Konzernforschung, 2001]

Profile bending/

forming

Complete the

frame

Sheets on

accumulative

skid

Modules to the base frame

Injection

molding of the

outer parts

Press

sheets

Add profiles to

the framework

Roof paint-spray

line

Painted component parts

to module assembly

areas

Base frame

assembly

Module

assembly


Semi-finished products-manufacturing technologies of

Al-space frames

[Projekt Faszination Karosseriebau]

Formed metal parts

Cast components

Extruded profiles



Vehicle Development Process

Manufacturing Processes

(state-of-the-art)


Existing & theoretically possible structural concepts

Applied and new methods of component manufacture and assembly

Technology Catalogue

[R. Hohmann: „Systematische Analyse und Machbarkeitsstudie von Karosseriekonzepten für eine

wirtschaftliche Kleinserienfertigung“, Diplomarbeit Inst. f. Konstruktionstechnik, TU Braunschweig, 2003]

Vehicle concept

construction matrix

Technology

catalogues

Concept tree

structure concepts

Vehicle concept

Target market

Customer group

Investments

Direction of

optmization, …

Quantifying &

Selection

Luxury vehicle

Small quantities

Cost-cutting

Time, Supplies

...

Application optimized structure concept

Delivery

conditions


Technology catalogues - Excerpt from a sample

[Th. Krusche, R. Koschorrek: "Konstruktionsmethodik und Karosseriekonzepte", Symposium anlässlich des 60. Geburtstagesvon

Prof. Dr.-Ing- H.-J. Franke, Braunschweig, 2004]

-solution catalog

- Classification

- Technical criteria

- Technological criteria

- Economical criteria

-Evaluation and weighting of the

procedure on quantity

Technology catalogue thermal joining methods

}


Overview of advanced manufacturing technologies

Patchwork technology

Thin wall steel casting

Multifunctional large castings

Colored plastic film

Tailor Rolled Blanks

IHU

Extruding

…


Examples of advanced manufacturing technologies

[Th. Krusche: "Stahl - Neuere Entwicklungen für den Karosseriebau", Werkstofftag Volkswagen AG, Wolfsburg, 2001]

Thin wall steel casting

• Local thickness differentiation

Weight reduction

• Cost advantage over welded

circuit boards

• Local thickness differentiation

Weight reduction

• Component integration

Patchwork technology


Multifunctional casting – middle water tank


Audi A8 (D2)

7 components: 5554 g

Audi A8 (D3)

4 components: 3742 g


Development of multifunctional castings

[H. Engelhard: "Der Einsatz von Aluminium im Karosserie-Rohbau am Beispiel des ASF® der 2. Generation des Audi A2", 2. Deutscher

IIR-Werkstoffkongress 2001. Stuttgart, 2001]

Components: 6

Mass : 4180gComponents: 1

Mass: 2300 g

High-Q-casting

Permanent mold

castings parts

Profile

Sheet

1150 1220

Pillar B Audi A8 (D2) Pillar B Audi A2ASF®


Shell construction / deep drawing

[Volkswagen AG, Entwicklung Karosseriestruktur E1 und Korrosionsschutz, 2005]

Example Passat B6


Colored plastic film


Preheating

Vacuum

Material for core-back

injection molding

Deep-drawn, colored foil

back injection molding

deep-drawn, colored foilColored foil


Examples of advanced manufacturing technologies - Tailored

Blanks

[N.N.]

Laser welded inner door panel

Laser weld

Laser welded wheel arch

Conventional differential design

(spot welding)

Integral „Tailored Blanks“

Laser weld


Variable wall thickness

[Th. Krusche, "Flexibles Dickenwalzen", Volkswagen AG, 2000 ]

• Increases: 1:40 to 1:1000

• Continuous process

• No welds

Lightweight Technology


Production and properties of flexible rolled sheet metal

[C.-M. Honsel: "Entwicklung eines Crash Management Systemens (CMS) aus hochfest flexibel

gewalzten Stählen", VP Business Development, Magna Cosma, VW TechShow, Wolfsburg, 2004]

Stress distribution:

Weld vs. sheet metal thickness transition

Checking of the deep drawing

Quelle: RWTH Aachen, Institut für Bildsame Formgebung

• Consistent sheet thickness

• Harmonic stress distribution in the sheet

thickness

• Uniform surface

• No notching effects

• No structural damage by welding

• Easily deformable

The material and forming

characteristics of flexible and

conventionally rolled sheets are

comparable


Component Examples

[P. Böhlke, "Übersicht Flexibles Walzen", Institut für Bildsame Formgebung der RWTH Aachen, 2002]

Sheet thickness1,60mm / 2,60mm / 1,40mm

Sheet thickness 2,00mm / 1,20mm / 2,00mm

Car body part (longitudinal chassis beam)

Car body part (cross beam)


Applications of TRB in the body structure

[C.-M. Honsel: "Entwicklung eines Crash Management Systemens (CMS) aus hochfest flexibel

gewalzten Stählen", VP Business Development, Magna Cosma, VW TechShow, Wolfsburg, 2004]

Cross beam rear seat

left/ right

2,0mm – 1,4mm –

2,0mm

ZStE 250/300 TRB Z100

Cross beam front seat

left/ right

2,0mm – 1,4mm –

2,0mm

ZStE 250/300 TRB Z100

longitudinal chassis

beam SGS

1,8mm – 2,8mm –

1,8mm

ZStE 250/300 TRB Z100

Heel support

1,2mm – 0,7mm –

1,2mm

ZStE 420 TRB Z100

Achieved improvements:

• Improved side impact behavior

• Parts reduction 19-7

• Realized cost savings potential


Closed profiles - Enlargement of TRB-technology

[P. Böhlke, "Übersicht Flexibles Walzen", Institut für Bildsame Formgebung der RWTH Aachen,

2002]

Profiles adjusted to forces Crash-Boxes

IHU-components

0,80mm

1,00mm

1,20mm

0,70mm

1,40mm

0,80mm

0,80mm

1,40mm

TRB-production processes

· Deep drawing

· Stretch drawing

· IHU

· Bending

· …


BMBF – Joint Research Project HIPAT

Objective: Accelerating the development and market launch of a new generation of

light weight profiles by roll forming high-strength tailor rolled blanks

Development DP-Steel (Salzgitter Mannesmann Forschung)

Tailor rolling(Muhr und Bender)

Roll forming(Welser)

Application(Schmitz

Cargobull)

Process development(PTU Darmstadt)

Design methodology (IK)


ClassificationMain

partAccess part

By cross

section / profile

3D-

model,

standar-

dized

Modular functions

Further

access

features

BMBF – Joint Research Project HIPAT

Objective: Accelerating the development and market launch of a new generation of light

weight profiles by roll forming high-strength tailor rolled blanks

Function-oriented object catalogue with HI-PAT profiles


Internal high pressure forming (Hydroforming)

[P. Richard, Firmenpräsentation UGINE, Wolfsburg, 2001]

Hydroformed 304 member

Porsche Boxter

Th.2.4mm - Dia 38mm


Hot Air Expansion Technology - Forming of hollows

[HEATform GmbH, www.HEATform.com]

Air

pressure

Thermal element

1) The insertion of the tube 2) Commencement of moulding

3) End of the axial forming 4) End of the calibration

axial

force


Internal high pressure forming (Hydroforming)

[P. Richard, Firmenpräsentation UGINE, Wolfsburg, 2001]

Inside : HF

seamweld

behaviour

Hydroformed

304 stainless steel node


Hydroformed side roof frame, 3D curved


AA

B

B

C

C

A-A

B-B

C-C

Roof frame overall length :

Wall thickness:

3000 mm

4,5 mm


Internal high pressure forming structure – rear longitudinal

chassis beam

[Th. Krusche, H.Walter, K.-U.Dudziak:"Untersuchung und Erprobung einer Stahl-Spaceframe-Struktur aus Innenhochdruck umgeformten

und rollprofilierten Bauteilen",FB P367 Studiengesellschaft Stahlanwendung. Düsseldorf, 2000]


Behavior of a hydroformed component in side crash

[Th. Krusche, R. Koschorrek: "Konstruktionsmethodik und Karosseriekonzepte", Symposium anlässlich des 60.

Geburtstages von Prof. Dr.-Ing- H.-J. Franke, Braunschweig, 2004] Y intrusions at 60 ms [mm]

Hydroformed B-pillar with extruded sill

(2.5 mm aluminum 8.0 kg per side)

Roof frame

B-pillar

sillboard

B-pillar at the shell construction

(steel)

Crash Gain

Hinge-joint reinforcement of

the B-pillar on the bottom

Adjustable safety belt

Holder interior lining

Reinforcement

Adjustable B-pillar

inside (not shown)


Combined forming operations of a roof frame

Roof frame:

Challenge: Adjusting the roll profile to the given distribution and the given cross sections

Solution in cooperation with Wagon:

Roll profiles:

• Front embossed

• Rear widened

• Stretch bending

• possible necessary stamping operation

Nevertheless: significantly cheaper than IHU

stretch bending

compressed

widened

Fzg. p.a.

Fertigungs-

kosten

(abzügl

Material)

Werkzeug-

kosten Invest

IHU 30000 100% 100% 100%

IHU 60000 97,60% 100% 100%

Streckbiegen 30000 75,40% 106% 24%

Streckbiegen 60000 73% 106% 24%

Vehicles p.a.

Manufactur-

ing costs

(less

material) Tool costs Invest

Stretch bending

IHU


Combined forming operations of a roof frame

In integrated steps, the embossed profile is

bent and stretched into the desired shape

for the final part.

Then, cut or punch operations can be

performed on the the flange.

Proposal of "Wagon" for a roof frame:

• Roll profile

o rear widened

o front embossed

o subsequent stretch bending


Extrusions

[H. Engelhard: "Der Einsatz von Aluminium im Karosserie-Rohbau am Beispiel des ASF® der 2. Generation des Audi A2", 2. Deutscher IIR-

Werkstoffkongress 2001. Stuttgart, 2001]

Phases of the manufacturing process

Extrusion and

trimming

Hydro calibration Finishing

conditioning

Die

Dummy block

Pick-up Die plate Profile

Filling

system

Profile

perforate, final cut

Component cleaning/

surface conditioning

Artificial aging to

increase the strength


Extrusions

[Projekt „Faszination Karosseriebau“]

Using the example of

extruded profiles of the

undercarriage from the

project "Fascinating

body construction"





(Joining Technology)


Construction method -joining systems


Metallic Mixed construction FRP / composite construction Modular construction

• Resistance soldering,

(MIG) brazing, bonding

and mechanical joining

of Al / St, and Mg / Al

• Welding, adhesive

bonding and mechanical

joining of stainless steel

structures

• Joining in the assembly

• Joining of surface-refined

components

• Structural joining of

FKV-St/-Al/-Mg

(Mechanical joining and

bonding)

• Design and

investigation plan for

-problem


Joining technology for new constructions


Metallic mixed construction

FRP / composite construction

Modular construction

Cost-effective and functionally light vehicle structures

Extension of existing process limitations

Building-specific redevelopment

Welding

Brazing

Mechanical Joining

Bonding

Hybrid Joining

High-strength

steel

Stainless steel

Aluminium

Magnesium

FPC

Active fluid mediabased forming

Roll profiling

Extruding

Castingtechnologies

Injection/ pressingtechniques

Objective:


Joints design


Use of additional elementsPlug solutions

Welding solutions

Quelle: JüttnerQuelle: Meschut

Quelle: TKS


Schematic structure of the body skin structure –

A/A0 segment state Golf IV

[Th. Krusche, "Projekt Faszination Karosseriebau", Volkswagen AG, Konzernforschung, 2004]

Chassis IGeo station

welding

Chassis IIGeo station

welding

Side partsGeo station

welding

RoofGeo station

welding

Attaching

parts

• Used joining techniques:

- Spot welding

- MIG/MAG

- Laser welding

- Bonding

- …


Joining techniques - VW Passat

[H. Friedrich, H.-G. Haldenwanger: "Leichtbaustrategien und Trends: Wettbewerb der Bauweisen und Werkstoffe", Bad Homburg, 2001]

High-strength sheet metal

Bonds

Laser seam

Platinum Technology


Laser welding

[H. Engelhard: "Der Einsatz von Aluminium im Karosserie-Rohbau am Beispiel des ASF® der 2. Generation des Audi A2", 2. Deutscher IIR-Werkstoffkongress 2001.

Stuttgart, 2001]

Laser welding

Laser welded seam

Advantages of laser welding:

• Linear welded seam

• Low flange width at lap joints

• Unilateral accessibility by

deep-weld effect


Seamless connection with laser soldering

[Volkswagen AG, Entwicklung Karosseriestruktur, 2002]


Punch rivettings

[H. Engelhard: "Der Einsatz von Aluminium im Karosserie-Rohbau am Beispiel des ASF® der 2. Generation des Audi A2", 2. Deutscher IIR-Werkstoffkongress 2001. Stuttgart, 2001]

Punch rivettings

Punch rivetting connection

at the rear end plate


Elastic bonding with the roof assembly

[J. Wieschermann, A. Starlinger: "Über den Einsatz von Hybridbauweisen im modernen Schienenfahrzeug- und Busbau", Leichtbau-Symposium Dresden, 2002]

Aluminium layer

Aluminium layer

Foam core

Aluminium profile with C-bar

Elastic glue joint

Elastic glue joint

Aluminium

roof frame

Gasket

Spacer

Beading edge





(Corrosion Prevention and Paint)


Corrosion protection at Volkswagen

Road salt induced

corrosionAtmospheric

corrosionAir temperature, air

humidity, air pollution

Dynamic vehicle

load

Damage to surface coatings

and waterproofing

Blunting means

Gritt, chippings,

granules

Dirt deposits

Splashing water, mud

and salts

Freezing rain

Cracks in the corrosion

protection through ice


High mountainareas

Summer:warm, wetWinter:cold, dry

Summer:warm, wetWinter:very cold, dry

Summer:cold, dryWinter:very cold, dry

Summer:medium, wetWinter:medium, wet

Summer:warm, dryWinter:medium, wet

Summer: warm, dryWinter:cold, dry

Summer:warm, dryWinter:medium, dry

Summer:very hot, humidWinter:hot, humid

Summer: hot, humidWinter:Hot, dry

Humidity

Water

Heat

T (°C)

Solar radiation

Cold, ice,

snow

Ozone O3

Salt

Climates and weathering conditions

[Volkswagen AG]


Corrosion protection in the development

Task: to ensure fulfillment of this guarantee even in the setting of development design,

materials and manufacturing technology, so that corrosion can be prevented / reduced

Seam sealing

Underbody protection

Cladding and structural

corrosion protection

zinced

Paint system Wax conservation


Corrosion protection measures for the VW Golf 6:

Galvanised body

Lacquer coat design based on the process 5a

Rough seam sealing, fine seam sealing

Cap

PVC coating

Cavity protection

Attachments to the underbody

Corrosion protection on the example of the Golf VI

[Volkswagen AG]


Seam sealing

[Volkswagen AG]

Rough seam sealingon the example of the front wheel

arch

Fine seam sealingto the attachments

Inner sheet

Outer sheet

Fine seam sealing


Plugs and PVC underbody

[Volkswagen AG]

Cap on the example underbody

Car body

Plug

Installation situation:

PVC-coating on sills

Stone chip protection sill

Abrasion protection for

KU rear wheel house

(will be applied from the

inside)


Underbody protection, preservation of hollow spaces

Rear wheel

arch shell (KU)

Cw- gound cover (KU)

Front wheel arch

shell (KU)

Motor casing (KU)

Heat shield plates (aluminum) also

undertake stone-chipping protective

function

Tank undertakes stone-

chipping protective

function

Attachments - Underbody protection Preservations of hollow spaces

Preservation of hollow spaces by

wax flooding the hollow spaces

(sills, rails, etc.)

Preservation of the lower door groove

either by wax flooding or by manual

spraying of wax


Surface protection and paint system


Zinc layer 7µm-10µm

Phosphate layer 3µm

Cathodic dipping paint 20µm

Filler 30µm

Base coat paint up to 20µm

Clear paint up to 40µm

Flood wax <500µm

Chromophore

periphery

Measures for corrosion

protectionSteel


Drying parameters


HRK

Decklack

Basislack

Waschen

Füller

KTL

0

20

40

60

80

100

120

140

160

180

200

Temperature in °C

40min. 20 min. 20 min. 5 min. 30 min.

5min.

Drying times

Cooling to about 35 ° C for further

processing

Filler

Wash Base

coat

paint

Roof paint


Agenda

1. Motivation

Vehicle history

Vehicle environment

2. Inauguration


Car concepts


Goal definitions

Costs

Materials




Virtual reality


Package

Design



Modularisation

Safety


Special need for theoretical investigations in the form of simulation calculations early in the

development of the vehicle or the body, when no parts are available for testing. In particular,

the computational procedure can be divided into two groups:

• Investigations of the entire vehicle

• Investigations of sub-systems

For the conception and the design of the body, both methods are used.

The aim is to define the design through numerical simulation.

IT, models and tools


Simplified FE-body model

a-z: brackets

1-7: nodes

Metal surfaces are not shown

Simplified FE model car

Total vehicle, see also CAE lecture.

IT, models and tools, static and dynamic


Detailed FE-body model

IT, models and tools, static and dynamic


Steps of the component design

[Audi AG: "Schritte der Bauteilgestaltung"]

Definition of the component geometry in the

constructional system environment

Analysis component requirements profile Material selection

pre-dimensioning

Primary data (scores)

Secondary data

(features)

Component calculation CAE

structural analysis

- Stiffness/ stability

- Static-dynamic stability

- Vibration analysis

- Durability analysis

CAD design component geometry

Adjustment (iterative)

Plastics: rheological calculation by 2D-3D-CAD/CAE (Cadmould, Moldflow, ...)

Metals: shape completion and solidification simulation (Magma, ProCast, Simtec, Simulor...)

Adjustment (iterative)

Tool design with CAD / CAE (geometry, rheology, heat balance, strength ...)


FlexBody – Application for Modular Vehicle Structures

Examples for FlexBody structures

4-Seat Compact Sports Car (Capro) 6-Seat Compact Van (FunVan)

Source: Imperia GmbH

The aim of this project is to develop a procedure that generates a cost-effective car body

using body-on-frame construction based on an intelligent modular construction system

within the shortest development and construction period possible.


FlexBody – Application for Modular Vehicle Structures

2 … 5-arm-joints

Standardisation of body joints

Increase in units

Reducing parts costs


Overview of CAE (calculation method) - not FEM - rigid body mechanisms

Source: AGELIDIS, N.: 3-D Crash Analysis using ADAMS

SAE-Paper 885076, 1988

Calculation methods, computer tools, models and tools


Overview of CAE (calculation method) - not FEM - First Order Analysis



Overview of CAE (calculation method) - Finite element method

3102

m

kg

T

BIWNmAC

m Analytical formalism low informational value

highest level of abstraction

extensive data collection

Spring-mass model low informational value

high level of abstraction

difficult data collection

Rod model moderate informational value

(FE-rod model) high level of abstraction

moderately difficult data collection

Shells / bar hybrid model good informational value

(FE-shell / beam) medium level of abstraction

simple data collection

automatic coupling possible

Shell/ bar hybrid model best informational value

Realistic components low level of abstraction

(FE-Shell/ beam) simpliest data collection

automatic coupling possible

FE

M m

od

els

Oth

er

mo

de

ls



• The finite element method has been able to push through since the early days - about 1960 –

as a very adaptive numerical method

• It was developed with the advent of the computer systems of classical structural analysis and

is used in almost all engineering applications

• The importance of the method is based on the uniform approach to various problems

• Basically, it is always the same solution approach for a two-or three-dimensional structure

• Complex structures can firstly be built with this method

• However, the finite element method (FEM) is an approximation method!

Calculation methods, computer tools, models and tools - finite element methods - Summary


• Unique simulation models for all modes

• Major components for frontal impact

P/T assembly

wheel and chassis assembly

instrument panel

fuel system

load cases (i.e. barrier types, dummies etc.)

• Manual assembly process

time inefficient

error sensitive

no update compatibility

Radioss Simulation

Model

Frontal Impact Crash Model

Frontal Impact Crash Components

Finite element method - Crash Simulation – Overview model assembly and simulation chain


Active include files example: P/T and P/T mounts only

Model components in pre processor

Finite element methodsCrash simulation – Overview – Module


Today:

> 1.000.000 Elements

Finite element methodsCrash simulation – Overview

Year

Development of models for the frontal crash

Model S

ize &

Com

ple

xity

300000 elements

80000 elements

6000 elements

500

elements


t = 60 ms t = 120 ms

Finite element methodsCrash simulation – Overview


Overview of CAE (calculation method) - Finite element method



Overview of CAE (calculation method) - rigid body simulation

15ms after TTF



Overview of CAE (calculation method) - rigid body simulation



SFE Concept – A Tool for Fast Parametric Engineering Design


SFE Concept – A Tool for Fast Parametric Engineering Design

Rapid prototyping: Quick, easy and

accurate topology & geometry model

creation for with design constraints

Implicit parameterization “NO” additional

time for parameterization

Easy model variation

Integrated Finite Element Generator

Store models and components in library for

generation of knowledge database and

reusability

Shape & size optimization in closed batch

loop

On-the-fly definition of design variables and

design space

Integration of specific applications like

commercial optimization and design tools


Agenda

1. Motivation

Vehicle history

Vehicle environment

2. Inauguration


Car concepts


Goal definitions

Costs

Materials




Virtual reality


Package

Design



Modularisation

Safety


Virtual Technologies - Definition

■ Virtual reality VR = real-time applications

■ Augmented Reality AR = Mixed Mock-Ups in real time

■ Digital Mock-Up DMU = data bases and application programs

■ Calculation / simulation, for example finite elements, fluid flows, etc.

realvirtual

Source :Audi EK

Virtual Reality Reality

[W. Schreiber: "Visualization Techniques to Accelerate Product Development", Volkswagen AG, 2005]

Augmented Reality


Objectives

Acceleration of the development process

Frontloading

Software rather than hardware, "look before you build“

Increased quality

Identification of problems in early stages

Improvement in prototype quality / production quality

Verification of all options or derivatives

Simple verification of manufacturability and operation

Cost reduction

Reduction of development time and time-to-market

Reduction of models and prototypes

Lowering of the modification effort



Innovation in the development process


Virtual box seat Ergonomics Simulation Virtual Vehicle

Concept Development Series Development Series Preparation


Virtual cockpit

Virtual driver‘s seat:

model of the interior of a vehicle

Clearance distance

Visibility inside, outside

Sense of space

Reachability

Representation of real and planned components

Simple representation of variants and derivatives

Very early use in the development process

Cost and time savings



Ergonomics

Insertion of people in the virtual scene

Intuitive interaction with the scene

Analysis of operating concepts

Ergonomics analysis

Simple representation of

variants and derivatives

Analysis of different body

measurements of the user



Simulation

Representation of stresses

Assembly of hoses

Installation of cables and connectors

„Design in the loop“

Preliminary design

Simulation of, for example, deflections

Reduction of development iterations

Higher quality in preliminary design stage



Virtual vehicle

Real-time calculations

Light

Reflections

Shades

Realistic and dependable illustration

Quantifying of the appearance of the vehicle

Illustration

Different colors

Complete Vehicles

Quicker preparation of design decisions


Comparison

real - virtual


Product-related innovations

Concept Development Series Development Series Preparation

Virtual

assembly

Robot programming

Analysis of

Interference

Virtual Seating Buck

Ergonomics

Simulation

Virtual vehicle



Virtual assembly

Determination of assembly sequences

Reachability of the workspaces

Easy part fits

Usability of tools

Ergonomics analysis

Posture

Load

Collisions

Early confirmation of the preliminary design



Analysis of Interference

Representation of plans in

real environment

New products

New equipment

Safety

Safe and easy planning of new

production facilities



Robot programming

Representation

Paths of motion

Coordinate systems

Interference check of virtual paths

Manipulation of virtual paths

Staff training

Avoiding of errors in the processes


2 Vehicle Development Process & Para Metrical Car Body Design_II

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