INCORPORATION OF MANUAL GEARSHIFTER

KONG PHAN CARLOS ROJAS TENA

Master of Science Thesis Stockholm, Sweden 2016

Incorporation of Manual Gearshifter A Robust Design Engineering Solution

Kong Phan Carlos Rojas Tena

Master of Science Thesis MMK 2016:158 IDE 181 KTH Industrial Engineering and Management Machine Design SE-100 44 STOCKHOLM

Examensarbete MMK 2016:158 IDE 181

Integrering av ett manuellt spakställ

Kong Phan Carlos Rojas Tena

Godkänt Examinator Handledare 2016-09-28 Claes Tisell Conrad Luttropp Uppdragsgivare Kontaktperson Volvo Personvagnar Linda Karlsson Sammanfattning Syftet med projektet var att undersöka huruvida det var möjligt att integrera det manuella spakstället i Volvo Personvagnars modell, S90. Projektet fokuserade på en integrering utav spakställshuset i tunnelkonsolstrukturen då den nuvarande lösningen är onödigt stor och hämmar för andra potentiella funktioner.

För att få en djupare förståelse i uppgiften och ta fram en kravspecifikation för konceptlösningen gjordes observationer och intervjuer på bland annat företagets monteringslina samt dess underleverantörer relevanta för projektet. Faktainsamlingen omvandlades till utmärkande egenskaper med mätbara enheter via implementering av en QFD, kundcentrerad kvalitetsutveckling. Detta utgjorde grunden till konceptgenereringen som resulterade i två huvudkoncept av olika spakställ samt tunnelkonsolstrukturer. Dessa konceptlösningar genomgick en itererad process av FEM analyser som utvärdering.

För val av koncept att vidareutveckla användes beslutsmatriser. Det utvalda konceptet optimerades med avseende på industriell tillämpbarhet, då aspekter som tillverkning och montering beaktades. Resultatet av det slutgiltiga konceptet var ett nytt mindre spakställshus som fästes på tunnelkonsolstrukturen, vilken hade en integrerad vajerhållare.

Det slutgiltiga konceptet klarade de hållfasthets- och styvhetskrav som ställdes. Konceptet är lättare än den befintliga lösningen samtidigt som den fick en lägre materialkostnad med reducerad volym. En kostnadsanalys på den nya lösningen visade att konceptet blir lönsamt efter ca 120 000 tillverkade bilar med manuell växellåda.

Den robusta konceptlösningen är hållfasthetsmässigt genomförbart, det behöver dock ytterligare granskning vad gäller NVH och utmattning för att kunna gå i produktion.

Master of Science Thesis MMK 2016:158 IDE 181

Incorporation of Manual Gearshifter

Kong Phan Carlos Rojas Tena

Approved Examiner Supervisor 2016-09-28 Claes Tisell Conrad Luttropp Commissioner Contact person Volvo Corporation Linda Karlsson Abstract The main scope of the project was to investigate whether it was possible to integrate the manual gearshifter of the Volvo Car model S90, into the tunnel console framework, since the current setup is excessively space occupying. In order to gain a deeper understanding of the scope and establish a requirement specification for the concept solution, observations and interviews were conducted at the assembly factory and relevant suppliers. These findings were converted to different characteristics with measurable units employing a QFD, which was the basis for the concept generation. The concept generation yielded two main concepts of different kind of manual gearshifters and tunnel console frameworks, which were evaluated using FEM analyses. Since both main concepts passed the requirements, concept decision matrices were employed to select the concept to further develop. The chosen concept was optimized to be more industrially applicable in terms of manufacturing and assembly. This resulted in a final concept, including a new smaller manual gearshift housing that was attached to the tunnel console framework, which had an integrated abutment bracket. The final concept passed all the established requirements, and resulted being lighter than the current setup. This in turn, resulted in a lower material cost for the new concept setup, which would be profitable after approximately 122,000 manufactured vehicles with manual , according to an assumption in the cost analysis. The robust concept solution was feasible, in terms of solidity, it does however need further assessment in NVH and durability in order to go into production.

Foreword This report covers a 20-week Master Thesis project for the Masters’ program Industrial Design Engineering at KTH Royal Institute of Technology. The project was conducted at Volvo ’ department in Gothenburg, Sweden during the spring of 2016.

We would like to thank our supervisor Linda Karlsson at with her guidance and knowledge in order to fulfill our objectives. We would also like to thank our supervisor at the institute, Conrad Luttropp, for his helpful supervision during the project.

Magnus Karlsson, for being an organizational help and guideline for us throughout the project, which was much appreciated. Lastly, we would like to thank the department 97700 for all their support and help during our stay in Gothenburg.

Kong Phan & Carlos Rojas Tena

Stockholm, September 2016

Table of Figures

Figure 1. Volvo Cars SPA 54x Tunnel Console ...... 1 Figure 2. Manual Gearshifter next to a SbW gearshifter...... 2 Figure 3. Current Manual Gearshifter with cables in the Framework...... 3 Figure 4. Undesired parts of the housing are cut out...... 3 Figure 5. Volvo's SPA platform (Volvo Cars Corporation, 2013)...... 5 Figure 6. Volvo Cars' Cluster 90 car segment with ICE and PHEV powertrains for the SPA- platform...... 6 Figure 7. Volvo Cars' Cluster 60 car segment with ICE and PHEV powertrains for the SPA- platform...... 6 Figure 8. XC90 SPA platform with Automatic Gearshifter...... 7 Figure 9. S90 PHEV SPA platform with SbW gearshifter...... 7 Figure 10 – Manual Gearshifter connected to the gearbox through shift cables...... 8 Figure 11. Gearshift pattern...... 8 Figure 12. Volvo Cars’ SbW with fastening holes...... 9 Figure 13. BMW automatic gearshifter with fastening on different levels...... 9 Figure 14. Manual Gearshifter hand-mounted on the magnesium plate (Volvo Cars, 2016)...... 11 Figure 15. Tunnel console mounted on the SPA platform by two assemblers (Volvo Cars, 2016) ... 12 Figure 16. Abuse load requirements of the integrated Manual Gearshifter into the Framework...... 17 Figure 17. Pre Assembly Line, Bay at C-Factory...... 18 Figure 18. Assembly tree of the main Console assembly sequence...... 19 Figure 19. Complete Console assembly sequence...... 20 Figure 20. The current Manual Gearshifter...... 23 Figure 21. Reduced housing of the Manual Gearshifter...... 23 Figure 22. The current SPA 54x Framework for manual transmission vehicles...... 24 Figure 23. Caption of area boundaries given from top view...... 24 Figure 24. Initial stage of brainstorming for Gearshifter...... 24 Figure 25. Brainstorming Manual Gearshifter with abutments...... 25 Figure 26. Brainstorming concept, bridge design...... 25 Figure 27. The Framework with its boundary conditions seen as red clamps...... 26 Figure 28. Von Mises stress value scale with the yield strength of PPLGF20 set as maximum...... 27 Figure 29. Mock-up representing the Manual Gearshifter integrated into the Framework...... 28 Figure 30. Framework Concept 1, added support to suit the integrated Manual Gearshifter...... 29 Figure 31. The Manual Gearshifter is fastened previous to the ...... 29 Figure 32. The Manual Gearshifter concept utilizing the cup holder support...... 29 Figure 33. FEM analysis on Concept 1 with the abuse load of 800N...... 30 Figure 34. Displacement of Concept 1 when applying 800N ...... 31 Figure 35. Concept 2, Manual Gearshifter a