TURKEY-KOREA WORKSHOP ON AUTOMOTİVE R&D … · · 2008-12-25TURKEY-KOREA WORKSHOP ON AUTOMOTİVE...

TEMSA R&D and Technology Inc.

TURKEY-KOREA WORKSHOP ON AUTOMOTİVE R&D 2008

TECHNOLOGY MANAGEMENT GROUP TEAM LEADER

VOLKAN BAYRAKTAR17.12.2008


• Turkey’s Most Valuable Holding Company• Main Operational Areas;

– Financial Services– Automotive– Industrial Yarn and Tire Manufacturing– Cement Industry– Retail Business– Energy– Textiles

• 2007 Consolidated Revenues 19,3 billion YTL• 2007 Net Income 969 million YTL

TEMSA is a wholly owned subsidiary of


TemSA was founded. Main activities were construction andcontracting projects19681968

Licensing agreement signed withMitsubishi

19841984

First licensed coach production19871987

First TemSA branded Midibus Prestij production19921992

Design of the first TemSA Bus Body20012001

History 1/2


Focusing on European Markets and foundation of “TemsaEurope”20022002

Establishment of R&D and prototyping center20032003

Diamond, Opalin, Powerbus20042004

HD Safari, Tourmalin20052005

TemSA R&D and Technology Corp., Metropol20062006

Metropol S, Prestij Super Deluxe20072007

History 2/2


Product Line-Up


TEMSA

DiamondSafari (HD, RD, IC)

SafirTourmalin

CBU’s

SALES AREASALES AREA

TURKEYTURKEY

Production

Bus Midibus Light Truck Commercial Veh. Passenger Cars Constructon Eq.MetropolOpalinPowerbusPrestij

Canter (Mitsubishi) L 300 (Mitsubishi)

L 200 (Mitsubishi)

Pajero (Mitsubishi)

Outlander (Mit.)

Lancer (Mitsubishi)

Colt (Mitsubishi)

Loader (Komatsu)

Forklift (Komatsu)

SALES AREASALES AREA

TTURKEY & INTERNATIONAL MARKETSURKEY & INTERNATIONAL MARKETS

TemSA Operational Areas


Temsa Adana• Total Land 555.000 m2• Covered Area 105.000 m2• 1639 employees• Annual Capacity:

– 1.000 bus– 2.000 midibus

TemSA Facilities

Temsa Egypt• Total Land 80.000 m2• Covered Area 30.000 m2• 750 employees• Annual Capacity:

– 500 bus– 500 midibus

Temsa R&D and Technology• 197 employees

– 92 Engineers– 43 Draftsmen– 3 Industrial Designers– 49 Technicians– 10 Others

Temsa Adapazarı• Total Land 150.000 m2• Covered Area 30.000 m2• Annual Capacity:

– 7.500 light trucks


R&D Branches

Product EngineeringDepartment

TemSA Inc. TemSA R&D andTechnology

• Temsa R&D Corporation works in close cooperationwith the R&D Department within Temsa A.S.

• Temsa R&D Corporation is responsible for;– developing new platform vehicles,

– developing design alternatives for ongoing vehicles,

– searching and implementing alternative material solutions.

• Temsa R&D Department is responsible for;– product development,

– documentation for serial production,

– corrective actions for serial production vehicles


Location


ü Concept and Technology Development

ü Technology Monitoring and Technology Transfer

ü Market Research

ü New Product Design/Analysis/Testing

ü Prototyping

ü Product Development

ü Project Management

ü Building National/Multinational Strategic Collaborations andProject Consortiums

ü Intellectual Property Rights Management

TemSA R&D and Technology


•March 2006 Foundation of the Company•June 2006 Starting Operations in TÜBİTAK-MAM Technology Free Trade Zone

TemSA R&D and Technology


AdvancedTechnologies

BreakthroughApplications

PlatformCreation

DerivedProducts

Current ProductPortfolio Support

Collaborative R&D Projectswith Research Platforms

Research Companies Established in Universities

Cooperation with Universitiesand Research Institutes

Internal R&D Operations

R&D Structure


Coach

Intercity

City

Midibus

Truck

Trailer

ProgramDirectors

Chassis Design

P/T Design

Electric/Electonic

Body Design

Trim Design

HVAC

Product DevelopmentManager

CAE

Homologation

Quality Assurance

R&D Workshop

Purchasing

Materials

Configuration

Validation & SupportManager

General Manager

Technology Management

Industrial Design

Organization Chart


R&D Division

Ø 91 EngineersØ 43 DraftsmenØ 3 Industrial Designers

Human Resources

Workshop

Ø 1 EngineersØ 49 Technicians


Human Resources

Education

Ø 2 PhDØ 50 M.sc.Ø 70 B.Sc.Ø 30 Associate Degree


TEMSA

R&D

Division

Corporate Strategy

Marketing Strategy

Resource Allocation

R&D Strategy

Product/Program Strategy

Project Management

Positioning the R&D Division


Design Validation Groups

PROGRAM MANAGEMENT

TemSA R&D Process Management


ChassisChassis CAECAE

Styling GroupStyling Group

PowertrainPowertrain TestingTesting

PurchasingPurchasing

BodyBody HomologationHomologation

MethodologyMethodology

Electric/ElectronicElectric/Electronic Quality AssuranceQuality Assurance

MaterialsMaterials

TrimTrim ConfigurationConfiguration

HVACHVAC

Program OfficeProgram Office

Des

ign

Spec

ializ

atio

n G

roup

sD

esig

n Sp

ecia

lizat

ion

Gro

ups

Valid

atio

n G

roup

sVa

lidat

ion

Gro

ups

Supp

ort

Gro

ups

Supp

ort

Gro

ups

Truck Program OfficeTruck Program OfficeMidibus Program OfficeMidibus Program OfficeI/C Bus Program OfficeI/C Bus Program OfficeCoach Program OfficeCoach Program Office

R&D WorkshopR&D Workshop

Technology Management GroupTechnology Management Group

City Bus Program OfficeCity Bus Program Office Trailer Program OfficeTrailer Program Office

Specialization Groups


Production

Employees

Customers

Competitors

Suppliers

Regulations

ProjectDevelopment andFeasibility Study

ConceptualDesign

Detailed Designand Engineering

Pre-SerialProduction

X+10 X+3 X+3 / X+1 X+1

Budgeting

Product Development Process


R&D Process

Market Research Technology

Monitoring and

Integration

Concept Development

Preliminary

Design

PrototypingTesting

Engineering Analysis


Design Revision

Production of

Final Prototype

Testing Final Prototype Engineering

Analysis

Homologation and

Type Approval

Testing

R&D Process


Ø Alternative Materials Characterization and Application

Ø Analysis and Integration of Alternative Powertrain Systems

Ø Weight Reduction Operations

Ø Simplification of Production and Assembly Systems

Ø Vehicle Dynamics Improvement Activities

Ø Development of Active and Passive Safety Technologies

Ø Intelligent Mobility System Applications

Ø Component based and full vehicle structural analysis, vehicledynamics and CFD analysis

Ø Emission, fuel consumption, engine performance, HVAC and vehicledynamics tests

R&D Activities


Ø Developing smarter, safer, environmentally friendlier vehicles

compatible with the transportation infrastructure

Ø Developing vehicles with high vehicle-to-vehicle and vehicle-to-

infrastructure communication capability

Ø Developing innovative conceptual designs for public and freight

transportation

Ø Customizing the vehicles for the special needs of institutions,

companies and individuals

R&D Objectives


CFDComputational Fluid Dynamics


Air Flow Analysis


<ψ>

<w>

Aerodynamic Tests


Strength AnalysisFinite Element Method and Analysis


Light Truck Cabin Roll Bar Bracket


Towing Hook Analysis


NVHNoise, Vibration, Harshness


• Riding Comfort Analysis,– Comparing the results with ISO 2631 standards

• Measuring Noise and Vibration,– Comparing the results with competitors and acceptable

values.

NVH Analysis, Driver and Passenger Comfort


Driver and Passenger Comfort Test


NVH - Modal Analysis


Durability Analysis


Old Design Process for Durability Validation and Verification


Test Centers - MIRA


Resonance Road

Belgian Pavement

Test Centers - MIRA


CAE

CUP (CustomerUsage Profile)

Current Design Process for Durability Validation and Verification


Data Entry to Simulate Turkish Intercity Roads


Force Direction and Magnitude Data Collection


Analyses of Vehicle Behaviors on Torsion


Analyses of Torsional Stiffness


Analyses of Vehicle Behaviors on Bending


Vehicle Dynamics Model


Simulation of Road Conditions on the Design


Behavior of the Vehicle on Belgian Pave


Vehicle SafetyRollover Analysis


Statistically the fatality rate is high in rollover accidents

Accident Statistics


Ø ECE-R66 is the regulation defining the minimum strength expected fromthe bus structure to minimize the fatality and injuries in rollover accidents.Ø ECE-R66 approval is requested in the countries that already adopted the2001/85/EC directive.Ø Criterion: No structural part of the bus should penetrate the survival space

ECE-R66 Regulation


ECE R66 Rollover Analysis

Crash & Safety


Dummy w/oSafety belt

Dummy with2 Point Safety Belt

Dummy with3 Point Safety Belt

Effect of Safety Belts During a Rollover Accident


Dummy w/o Safety Belt


Dummy with 2 Point Safety Belt


Dummy with 3 Point Safety Belt


Vehicle SafetyCrash Analysis


Braking Performance Tests


Braking and Stopping Distance


• Frontal Crash Model is analysed• Rigid engine, axles, fuel tank, air condition and wheels are used• The speed at crashing instant is 60 km/h

Model


Frontal Impact – 60 km/h


Diesel City Bus

Trailer

Hybrid Engine City Bus

Light Truck

Heavy Truck

New Generation Opalin/Powerbus

New Generation SHD

New Generation I/C

Fuel Cell City Bus

On Board Diagnosis System

Q1 Q2 Q3 Q4

2006

Q1 Q2 Q3 Q4

2007

Q1 Q2 Q3 Q4

2008

Q1 Q2 Q3 Q4

2009

Product Development Projects


New Bus Project (CityBus O101)

Ø Innovative vehicle design based on customer needsØ Alternative materials application for chassis and bodyØ Innovative joining methodsØ Strategical collaboration with Sabancı University and İstanbul

Technical University

R&D Projects


Alternative Fuel Vehicle Project

Ø Engine that meets Euro 6 and Tier2 Bin5 emission levelsØ Developing an engine power management system efficiently

operating at low rpm’s.Ø Low NOx and particulate emissionsØ Low fuel consumption and low CO2 emissionsØ Strategic Partnership with TÜBİTAK Energy Institute

R&D Projects


Light Vehicle Project

Ø Light and high durability vehicle

Ø Hybrid material use in chassis and body applications

Ø Innovative Joining MethodsØ Aluminum-composite light material city bus design and prototypingØ Strategic Cooperation with Sabancı University, ASAŞ, ASSAN

Aluminum and TÜBİTAK

R&D Projects


Project Proposal for SST-2007-RTD-1 Call

Ø Advanced telematics and ticketing system applicationsØ Customized interfaces for elderly and handicapped peopleØ On-board passenger flow optimizationØ Alternative engine technology applicationsØ Alternative material applicationsØ Consortium members from 6 EU countries and from different

competence and technology areas

R&D Projects


Project Proposal for ICT-2007.6.1. Call

Ø Driver fatigue monitoring and modelling technologiesØ Image processing and sensor fusion applicationsØ Use of internal and external monitoring and modelling

technologiesØ Consortium members from 9 EU countries and from different


R&D Projects


R&D Projects

Project Proposal for SEC-2007-2

Ø Development of early warning system for threats targetingtransportation infrastructure

Ø Application of video monitoring systems in publictransportation vehicles

Ø Developing an algorithm for the classification of the trafficdelays based on threat level

Ø Consortium members from 8 EU countries and from differentcompetence and technology areas


R&D Projects

Project Proposal for ICT-2007.6.1. Call

Ø On board data gathering systemsØ Application of GPS/GPRS communication technologiesØ Use of PDA interface for driver warningØ Consortium members from 5 EU countries and from different



R&D Projects

Project Proposal for SST-2007-RTD-1

Ø Advanced hybrid technology applicationØ Application of B100 fuel and fuel cell technologyØ B100 engine life cycle testing and hybrid technology

laboratory testingØ Consortium members from 6 EU countries and from

different competence and technology areas


“To be a World Class Global Brand”

TemSA’s Vision


“As a commercial vehicle producer,together, we create innovative solutions

for our customers”

TemSA’s Mission

TURKEY-KOREA WORKSHOP ON AUTOMOTİVE R&D … · · 2008-12-25TURKEY-KOREA WORKSHOP ON AUTOMOTİVE...

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