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Vehicle Architecture the Ultimate Road-Track Car Lotus Engineering The official industry newsletter of Lotus Engineering Issue 10 September/October 2005 Vehicle architecture The ultimate road-track car Lotus Engineering Change the Rules Welcome 22 It’s true to say that decisions on Vehicle Architecture, often made at the outset of a vehicle programme, can have a profound effect on a vehicle projects’ risk and profitability. This realisation, coupled with the need to reduce economic volumes of production, can add increasing pressure to large OEMs. This leads to the further exploration of alternative methods of vehicle construction and a possible move away from the ubiquitous steel monocoque. Our experience for vehicles at volumes up to around 10,000 p.a. is that a wide range of vehicle architecture and technologies could apply. Each one will have its own downstream implications for cost, quality, manufacturing and timing. Daryl Greig This issue of proActive looks at vehicle architecture and explores these points as well as typical approaches to the problem. I hope you will find it a useful comparison to your own organisation. Group Lotus PLC is named In addition we are also featuring a master class session with Matt Becker where he looks at the problems “World Class Manufacturer” associated with the loss of tyre adhesion. of the year 2005 I hope you enjoy this issue. The Manufacturer Magazine ranks Group Lotus as No. 1 Daryl Greig – Vehicle Architect, Lotus Engineering “It is a real testament to our staff who ha ve worked relentlessly to raise the standards of manufacturing, and 10 we are committed to continually looking at ways to improve in the future to ensure we remain a ‘ World Class’ Manufacturer.” Clive Dopson, Managing Director of Lotus Cars Contents September/October 2005 news features USA: Fuel cell specialist wields jobs axe 3 The ultimate road-track car 5 JAPAN: Nissan Motor to consolidate production engineering at home 3 Cruising without bruising 7 USA: Chrysler planning SUV product offensive despite petrol prices 3 Fuel economy proposals for the US: business as usual? 8 USA: Car makers call for government energy summit 4 Vehicle architecture 10 Modern vehicle architecture 12 Master class: A session with Matt Becker 14 Lotus Engineering Change the rules 2 News USA: Fuel cell specialist wields JAPAN: Nissan Motor to jobs axe consolidate production Fuel cell specialist Ballard Power Systems on Thursday engineering at home (22nd September) said it had cut 100 jobs and was reducing discretionary spending in an attempt to stretch available cash. Nissan Motor on Monday (26th September) said it would build a 5.1 billion yen facility near Tokyo to consolidate its global The Associated Press (AP) said the cuts eliminated full-time production engineering function in one place. positions at Ballard’s plants in Vancouver, Lowell, Massachusetts, and Dearborn, Michigan and left the company with about 600 Construction on the 30,000-square-metre facility in Zama, employees. Ballard said it achieved about half the reduction Kanagawa Prefecture, will begin in October, with operations through normal attrition and the elimination of open positions. expected to start in March 2007, the automaker told Kyodo News. The belt-tightening should reduce annual operating expenses by Currently, Nissan’s assembly plants around the world conduct about 12%, Ballard reportedly said. The company will record a third-quarter charge of $2 million related to the labour cuts. their own trial production and quality analysis. AP said the company said these expense reductions are “The new global production engineering centre will focus on in addition to savings it expects to realise from the recently drastically improving the quality of new vehicles through the completed sale of its fuel cell support systems business to concentrated trial production and quality analysis of new vehicles DaimlerChrysler and Ford. Both automakers own sizable stakes in all stages of production, from press shop to trim and chassis,’’ in Ballard. Sadao Sekiyama, a senior Nissan vice president for vehicle engineering production, told the news agency. these expense “This should further enhance vehicle quality levels at Nissan’s plants in Japan and overseas.’’ reductions are in Source: just-auto.com editorial team addition to sa vings USA: Chrysler planning SUV it expects to realise product offensive despite from the recently petrol prices completed sale of Chrysler Group is making a big bet on sport-utility vehicles at a time when rising petrol prices have focused attention on fuel its fuel cell support efficiency, the Wall Street Journal reported on Monday, according to Reuters. systems The newspaper reportedly said Chrysler is preparing five all-new SUVs for launch over the next few years as part of a product offensive that will also include a two-door Challenger sports coupe to compete with Ford’s Mustang, according to dealers and The news agency said that, during the second quarter ended in consultants briefed on the company’s plans. June, the company burned through about $28.7 million in cash, up from $22.5 million in the year-ago period. Ballard ended the The new SUVs mostly fall in the small and mid-size categories quarter with $231.3 million in cash and easily convertible assets, that have continued to sell well despite rising petrol prices that down from $240.3 million in December. have hurt demand for larger SUVs, the Journal reportedly said. According to the report, Ballard’s annual loss has grown from According to Reuters, it said DaimlerChrysler’s supervisory board $96.2 million in 2001 to $175.4 million in 2004 as the company is set to see a presentation of some or all of the SUVs and a half continues to pump funds into new technology. Yet, uptake dozen or so redesigns of existing Chrysler Group models at a has been slow as many automakers have opted to focus their dinner meeting on Tuesday night at the US unit’s design centre in investment on petrol-electric hybrids in the near term. Auburn Hills, Michigan though the plan is still subject to change. Source: just-auto.com editorial team Source: just-auto.com editorial team Lotus Engineering Change the rules 3 News USA: Car makers call for government energy summit Ford, Toyota and other automakers say they want the Bush administration to take more aggressive action to cut US dependence on petroleum, the Wall Street Journal reported on Monday (26th September), according to Reuters. As Hurricane Rita bore down last week on US Gulf Coast oil refineries, Ford chairman and chief executive William Clay Ford Jr. sent a letter to president George Bush asking for an energy summit involving automakers, suppliers, fuel providers, consumers and government officials, the newspaper reportedly said. According to Reuters, it quoted Ford as saying a summit would Potentially troubled times for William Clay Ford Jr focus on what the auto industry can do to find solutions for alternative fuel resources and that the recently signed $17 billion General Motors’ Washington spokesman, Chris Preuss, reportedly energy bill “is only the beginning.” told the newspaper GM welcomes calls by other automakers for more action on energy independence. Separately, the Journal reported that Jim Press, head of Toyota’s US operations, said he planned to go to Washington next month “We believe the US needs to begin aggressive energy policy to lobby lawmakers to make energy independence an issue in the moves away from petroleum toward hydrogen,” Preuss was election campaign of 2008. quoted as saying. “We should diversify our energy stocks away from foreign sources.” “We recognise the responsibility we have to come up with a solution to this economic problem,” Press was quoted as saying, according to Reuters. “As an industry, we should leave our individual companies’ bags outside the door to work together on “ We recognise this issue.” the responsibility we ha ve to come up with a solution to this economic problem ” According to Reuters, the newspaper said Ford’s call for an energy summit is another sign that the recent run-up in oil prices, and the post-Hurricane Katrina price spike that sent petrol prices above $3 a gallon, are forcing a rethink of energy strategy, particularly at GM and Ford. The news agency noted that the big Detroit car makers have long resisted proposals to increase government fuel-economy mandates for sport utility vehicles, pickup trucks and other light trucks, arguing that consumers would not want lighter, smaller, less powerful vehicles. As oil prices rise is hydrogen the solution? Source: just-auto.com editorial team Lotus Engineering Change the rules 4 Feature this with the help of a local professional team. So one Tuesday The ultimate night in January we decided to race the ‘yet to be delivered and I expect yet to be built’ Lotus Exige. So the team Rapid Chariots road–track car was born. Preparation What if you took an Exige S2 straight from the showroom and So what did we know about the Lotus Exige? Well apart from put it on the race track? How would it perform? Lotus enthusiast what we had read in the Lotus brochure, the usual magazine Rupert Laslett did just that. reviews and one TV episode of Top Gear, not much. So where do My friends call me a petrol-head, which is a good description as I you start? am mad about cars, especially sports cars. I blame this obsession on my father who in the late 60s worked as an aspiring engineer, We knew that in order to race the car, it had to comply with the for JW Racing (JW ran the Ford GT40 racing cars in the World minimum safety standards as defined in the ‘blue book’ (MSA Sports Car series).
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