HAVAL COUPE Body Lightweight Design and Attribute Integration
Dr. Lei Shi Technical Director R&D of Great Wall Motor
April 15, 2015 Detroit, MI USA Agenda
V Background
V Design Approach
V Lightweight Design
V Attributes - NVH - Safety - etc.
V Summary
2 Overview What we are? - We are China’s largest SUV and pickup manufacturer , with over 30 holding subsidiaries, more than 60,000 employees , four vehicle production bases and a production capacity of 800,000 units . - We own Haval and Great Wall brands , covering products range of SUV, passenger car and pickup . - Our assets had amounted to 61.345 billion RBM by Dec. 31, 2014. - We persist in focused development, uphold the brand concept of " focus, dedication and specialization " Our products: SUV, Pickup and Sedan 2014 SUV Top-ten Sales Ranking in China SUV 35 31.59 Unit: 10, 000 30 Top one: HAVAL 25 23.74 20 16.82 14.53 15 13.60 12.47 HAVAL HAVAL 11.45 10.70 10.06 9.87 10 5 - First produce economic type of SUV in domestic. 0 - Hover H6 got “China annual SUV prize” in 2012, which sales so popular and even hard to meet the purchase requirement. HAVAL H8 HAVAL H6 HAVAL Coupe-c HAVAL Coupe HAVAL H9 HAVAL H6 Update HAVAL H2
3 Overview What we are?
Pickup
- Domestic sales for GW pickup gains No.1 in 14 continually years. - Together with Toyota, Ford pickup named as “World three pickup”. - Trusted by 700,000 vehicle owner, and sales for more than 100 Countries and areas.
Saloon car C50 C30 C2OR C50 Update
- First made the saloon car in 2007, got No 2 in terms of sales quantity in 2011. - First pass EWVTA as Chinese self-owned saloon brand manufacture.
4 Overview What we are?
Pickup
- Domestic sales for GW pickup gains No.1 in 14 continually years. - Together with Toyota, Ford pickup named as “World three pickup”. - Trusted by 700,000 vehicle owner, and sales for more than 100 Countries and areas.
Saloon car C50 C30 C2OR C50 Update
- First made the saloon car in 2007, got No 2 in terms of sales quantity in 2011. - First pass EWVTA as Chinese self-owned saloon brand manufacture.
5 Overview What we are?
长城汽车新技术中心 Europe North America GWM New R&D Center China Japan
长城汽车欧洲技术分中心 长城汽车日本技术分中心 长城汽车北美技术分中心 GWM European R&D Center GWM Japan R&D Center GWM North America R&D Center (On-going)
6 Goal of R&D The goal of R&D activities: Background | Design Approach | Lightweight Design | Attributes
Over- design Style Freeze Data Freeze •T/Section •M/Section •Ext/Int •CAE & Physical •S.E. Test •Feasibility •S.E.. Report •Neighbor Parts Through Status Optimum - Data CAE design Freeze verification
Reduce Style Change & Data Change Under- design
How to freeze data? 7 Goal of R&D The goal of R&D activities: Background | Design Approach | Lightweight Design | Attributes
Design Change CutCut--offoff
Reach Performance Target within given cost and weight
Weight + Cost = Performance
8 Roadmap of WR Background | Design Approach | Lightweight Design | Attributes
Advanced Steel & Process Conventional Material & Process & More Light Material Cost
Maximum use of HSS & Process
Trad. Line D A Ideal Line B
C Opt. Body Performance Cost Cost Target Lightweight Design Cost & Weight saving Design
Optimum Design Process with CAE iteration multiple iteration of CAE
Weight Weight Target 9 Roadmap of WR Background | Design Approach | Lightweight Design | Attributes Strategy : Sequential effect/benefit for lightweight design
-A Kg -B Kg -C Kg -D Kg -E Kg Weight Weight reduction (Kg) reduction Total WR Total
Starting points
By secondary By thermal By aerodynamics weight reduction By weight resistance reduction reduction losses reduction improvement Fuel efficiencyFuel Total FEI Total
Efficiency benefit sequence: Mass reduction of passenger cabin and ripple effect will lead to greater fuel efficiency and secondary mass reduction
10 Roadmap of WR Background | Design Approach | Lightweight Design | Attributes Strategy : Sequential effect/benefit for lightweight design
-A Kg -B Kg -C Kg -D Kg -E Kg Weight Weight reduction (Kg) reduction Total WR Total
Starting points
By secondary By thermal By aerodynamics weight reduction By weight resistance reduction reduction losses reduction improvement Fuel efficiencyFuel Total FEI Total
11 Strategy of WR for Body Structure Background | Design Approach | Lightweight Design | Attributes Predecessor architecture BIW mass
Right size For a given set of conditions & Right loads, find the lightest & efficient topology structure that is able to meet design targets.
Right material Right Design details
New vehicle BIW mass
12 Strategy of WR for Body Structure Background | Design Approach | Lightweight Design | Attributes A MDO platform integrating all the vehicle attributes is developed to achieve the weight target under CAE environments
What is MDO? Multidisciplinary Design Optimization (MDO) is a methodology for improving design of engineering systems, e.g., automobile, aircraft, or spacecraft, in which everything influences everything else .
NVH : Torsion, Bending, Dynamic stiffness
Offset impact 偏置碰 : 64kph
Frontal正碰 ： 35mph
Madymo : FC1-USNCAP FC2-EuroNCAP
13 Door-ring Structure Background | Design Approach | Lightweight Design | Attributes Hot stamping process
1. Blanking 2. Blank heat up (over 900 degrees) 3. Forming & 4. Post form quenching operations
Remove
Weld Line
Predecessor HAVAL Coupe
14 Roof Cross-member Design Background | Design Approach | Lightweight Design | Attributes
Weld Line
Predecessor HAVAL Coupe
15 MDO- based Lightweight Design Background | Design Approach | Lightweight Design | Attributes
MDO Integration
BIW Trimmed-body Safety
Trimmed-body Full Frontal BIW NM VTF/NTF/IPI
Trimmed-body Bending Stiff Acoustic Mode 40% Offset
Trimmed-body Torsion Stiff Bending Mode Side Impact
Trimmed-body BIW IPI Torsion Mode Roof Crush
16 Front Seat Background | Design Approach | Lightweight Design | Attributes
To achieve 3.0 Kg weight saving per vehicle
17 Closure-Liftgate Background | Design Approach | Lightweight Design | Attributes
To achieve 1.71 Kg weight saving per vehicle while meeting design target requirements
18 LightweightIndex
0 Weight Predecessor 0 Kg egtrdcinLightweight index Weight reduction HAVAL Coupe -21.3 Kg
0 LWI Background | Design Approach | Lightweight Design | | Design Lightweight | Approach Design | Background Competitor 3.74 Predecessor 3.96 HAVAL Coupe 3.67 Attributes 19 Attributes Improvement Background | Design Approach | Lightweight Design | Attributes Attributes Available Space (AAS): VehicleAttributes − T arg etAttributes AAS = mean∑ T arg etAttributes
Predecessor HAVAL Coupe Predecessor HAVAL Coupe 0 0
+7% +8%
-18% -22% -26% AAS -29%
Safety attributes NVH attributes
20 Weight Reduction Background | Design Approach | Lightweight Design | Attributes Weight reduction summary:
Closures Seat IP 0
-1 Weight
0 Kg HAVAL Coupe 0 Predecessor Weight -5.09 -6.11 -21.3
BIW WR Total: 12.2 Kg
To achieve 33.5 Kg weight reduction w/o using light alloys
21 Summary
• Successfully developed a platform to integrate all vehicle attributes to achieve weight targets while meeting design requirements • Weight reduction: Totally achieve 33.5 Kg weight reduction w/o using light alloys Lightweight index has been improved 7.3% (through optimization of the body structure) as well as outperformed the competitor
• Vehicle attributes: Body rigidity-top class body rigidity performance through improvement of joint efficiency in all areas of the cabin Also, safety and NVH attributes are improved (w/ 7-8% enhancement) • Almost 40 RBM cost saving per vehicle with structural adhesive usage optimization
22 Thanks! Questions/Comments?
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