2015 Acura TLX Body Structure Review Aron Madsen Principal Engineer Cabin Technical Expert Upper Body Design
Honda R&D Americas, Inc. Introduction Agenda Acura Vehicle Lineup
Sedan SUV History of the Acura TL Sedan
3rd Gen - 2004
2nd Gen - 2000
4th Gen - 2009
1st Gen - 1996 History of the Acura TL Sedan
5th Gen - 2015 History of the Acura TL Sedan
Honda of America Manufacturing, Inc. Honda R&D Americas, Inc. Vehicle Production Design, Development & Testing Marysville, Ohio Raymond, Ohio
Honda R&D Americas, Inc. Concept, Package & Styling Torrance, California
Since 1998
Acura Dynamic Concept
SYNERGY work response MACHINE
MAN feedback input 2015 Acura TLX Concept Balance of Performance and Luxury
Magnetic Dynamic Design
RED CARPET ATHLETE
Engaging Intuitive Driving Experience Interactive Experience 2015 Acura TLX Concept
PROPORTION
PRESTIGE
PERFORMANCE Acura Sedan Proportion Hierarchy
PROPORTIONS that Offer an Invitation to Acura Performance & Prestige
(Discontinued) Wider 74.4 RLX 74.0 TL
73.0 TLX 72.4 TSX
70.6 ILX
Longer (Inches) 179.1 185.6 190.3 194.0 196.1 Proportion Changes
“Right Size” Package Dynamic Proportion – 0.5 inch*
-1.0 inch* (Width = 73 inches) * Compared to Outgoing TL Proportion Changes
“Right Size” Package Dynamic Proportion
– 1.1 inches* – 2.7 inches*
* Compared to Outgoing TL Proportion Changes
NO Sacrifice to Luxury Space
= Outgoing TL (Outgoing TSX + 1.8 Inches)
= Outgoing TL (Outgoing TSX + 2.8 Inches )
Proportions for Performance
Low Wide Stance Sloping Low Hood Proportions for Performance
Fast Rearward Cabin Short Rear Deck
Pushing Through Fenders Aerodynamic Design
Designed Using CFD, Scale Tunnel & Real-world Coast-down
Best in Class CD*A
Frontal Area* 15% Lower CD*A Compared to 12M TL
–1.5% CD*A
TL
2 JP EU TLX A4 JP
EU Front Area m Area Front * Compared to Outgoing TL
CD [ Acura Internal Data ] Clean Appearance, Aero Benefit
Visible Forward Forward Welds Edge Edge 15 TLX 12 TL Constant Curve No Welds Flange Not Constant
Roller Hem Wheel Arch
Rearward A Rearward A Edge Edge
Visible Welds A A Spot weld
Smooth Flange Not Transition to Bpr Constant SECTION AA SECTION AA Intuitive Cargo Loading
Opening Width Floor Length
+14% +12%
Lift Over Height
User Friendly Cargo Area • Increased cargo capacity/usability • Improved lift-over height
-15% Luxury Prestige
Cabin Comfort & Quietness Dynamic Refinement Dynamic Performance
THREE Levels of Performance
3.5L 2WD 3.5L 2.4L 2WD ** *
* Precision All-Wheel Steer ** Super Handling All-Wheel Drive
Body Concept & Development
Improve Ride and Improve NV and Handling Feel ENGAGING Appearance Quality
Solid Platform Acoustic Spray Foam Improve Mount Point Stiffness Enables a Quiet Cabin
MAGNETIC Optimized Body Apply High Tech Materials Where Most Needed
Hemmed RR Wheel Arch ENGAGING INTUITIVE Promotes Clean Appearance, Quality & Aero SMART Achieve Top Safety Pick+ Improve User Experience WIDE / LOW Opening
Manage Crash Performance Intuitive Cargo Loading Body Component Commonality
Upperbody is completely exclusive
Styling & Package Styling
Styling Safety: HSS590
Rigidity: Cast Mg Exclusive Components 30% Common Common Components Modified Components
Styling Body Construction Strategy
Optimized Body Structure for Performance ① Next Gen ACE Body Construction for Crash Compatibility and Handling ② Reinforced cabin for SICE / SOT ③ Rigid IP Frame and SUS Mounting Points for Handling and NVH ④ 4X Roof Crush and NVH 3 4 3 1
2 Material Type Application
52% Advanced High Strength Materials Durability
LSS 270 : 41% Aluminum : 6% Safety and HSS 340 : 3% Magnesium : 2% Durability Durability
HSS 440 : 5% Safety: SOT, SICE, Frontal HSS 590 : 35% HSS 780 : 2% HSS 980 : 2% USIBOR 1500: 5% Safety and 2% Rigidity 5% 6% Light 2% 41% Weight 2%
35% Safety: Light SOT, SICE, Safety: SOT, 3% Weight Frontal 5% Frontal Body Construction Strategy
Key Improvements in Body Structure, NVH, Crash Safety
Safety and Dynamic Performance
Optimized Body Hot Stamp Stiff Ring Manage Crash Performance
Targeted Stiffness Cast Mg IP Frame Acoustic Spray Foam Body Construction Strategy Optimized Global Midsize Platform Body Rigidity Body Rigidity + Road Noise Road Noise
( Targeted Stiffness Regions) Performance Achievement Key Body Stiffness Improvements Body Rigidity Body Rigidity + Road Noise Road Noise
Z +167%
X +69% Y +27% X +18% Z +31% Y +39% Z +6%
X +24% Y +45% Z +15% X +8% Y +17% X +21% X +132% Z +6% Y +27% Y +10% Z +46% Performance Achievement Body Rigidity for Static/Dynamic Performance RR Damper FR Damper 15M TLX 12M TL A B C D 37% 28% 42% 17% 30% -7dB -12dB
-4dB -10dB -10dB -7dB
N/mm Ave = 27% 10%
dB/N Ave = 8dB
Mount Point Static Stiffness Acoustic Sensitivity (20~300 Hz) Performance Achievement Body Rigidity for Static/Dynamic Performance
Global Bending Global Torsion 100N
+5 21% +5 White Body
Mass:
15M TLX 361kg
)
12M TL 386kg ° (Nm/ - 25kg
Eigen Frequency (Hz) Frequency Eigen (-55.1lbs) Torsion Global Modes Static Torsion Performance Achievement Body Rigidity for Passenger Comfort Level
15M TLX 12M TL
+31%
Rear +44%
Front Dyn Stiffness (N/mm) Stiffness Dyn
Seat Mount Stiffness Body Construction Strategy
Hot Stamp Door Ring Stiffener 1 Stiff Ring Benefits ① Improved energy management by uninterrupted joints that transfers load more efficiently. ② Improved door fit & finish by controlling front and rear door hinges on one part. 1 ③ 4.1 kg (9lbs) weight down by overall strength increase and eliminating weld flange overlaps. 3
980 MPa 2 1500 MPa 1500 MPa 3 440 MPa
1500 MPa
12M TL = 4 Separate Welded Pieces 15M TLX = 1 Piece, 1.4mm Thick Body Construction Strategy Cast Magnesium IP Frame 15M TLX 12M TL Cast Magnesium Aluminum/Steel Hybrid
Al
Fe Slip joint for stable vehicle impact performance
26 different parts: One tool casts Extrusions and stampings three parts • Difficult accuracy control • Higher accuracy control • High investment • High investment • Moderate Mass [7kg] • Mass savings [6kg] • ‘Acceptable’ steering frequency • Improved steering frequency Performance Achievement Cast Magnesium IP Frame Performance Strng Wheel Frequency Transfer Function
15M TLX 12M TL
Idle / Cylinder Mgt Zone +4Hz
Better -2.7dB
Better
-1dB
)/N]
2
Better
[dB/N] [(m/s
Idle / Cylinder Mgt Zone -1.3dB
Frequency [Hz] Frequency [Hz] Performance Achievement Optimized Body and Subframe Improve Driver Comfort
Front Axle Vibration as Felt by Driver Rear Axle Vibration as Felt by Driver
TL
TL Good
Good JP
EU JP EU – 61% JP EU – 31% EU
EU
Vertical G Vertical Vertical G Vertical – 46% TLX – 33% EU TLX EU Good Good
Fore/Aft G Fore/Aft G
High Level Static and Dynamic Optimization provide ideal ride and handling properties Performance Achievement Optimized Body, NV & Subframe Improve Driver Comfort Best-in-Class Road Noise Best-in-Class Wind Noise Cabin NV Levels Wind Noise Easy EU TL EU EU To JP
Hear JP EU TL Quieter
JP EU EU
Articulation Index Articulation JP Reduced dBA Frequency High TLX TLX Quieter
Low Frequency Drumming Mid Frequency dBA o Torsional Rigidity Improved by 21 % o Chassis Mounting Point Improved by 25 % o Body Leak Improved by 50% A Stiffer Body, with Higher Isolation & Sealing, was Required to Balance TLX’s NVH
Crash Safety Performance Complete Vehicle Safety Design Highest achievements in both consumer information testing & Honda requirements for vehicle-to-vehicle compatibility & pedestrian safety Rear Crash Consumer Information Testing Roof Crush IIHS SOT -- 64 km/h (& SICE) US NCAP -- Front 56 km/h (& SINCAP) Pedestrian IIHS ODB -- 64 km/h IIHS 4x Roof Crush IIHS Rear Impact Neck Injury IIHS Side MDB Side Impact Front Crash IIHS SUV (SINCAP (NCAP & ODB) &SICE) Honda Internal Testing Pedestrian Protection Small Overlap (SOT) Next Gen ACE TM Structure
ACE ™ [ Advanced Compatibility Engineering ] Crash Safety Performance IIHS SICE Crash Achievement
Result Judge Actual Survival Space 180mm GOOD Result Injury Measures FR / RR GOOD
CAE Prediction Crash Safety Performance IIHS 4X Roof Crush Achievement
Peak Load = 90.8 kN @ Plate Stroke = 76 mm SWR = 5.67
Result Judge
SWR 5.67 * (Peak Force) (90797) GOOD 2015 TLX Stroke 76 mm GOOD
* Benefit of SOT Pillar Structure creates large strength margin Crash Safety Performance IIHS Small Overlap Crash Management Zone ① Control G-Loading into body Zone ② Passenger Protection
25% Overlap @ 40mph
Passenger Protection with strong cabin Crash Safety Performance Door Ring Crash Management
USIBOR 1500 HSS 590 Outside HSS 980 HSS 780 Inside
Balanced blend of Very Rigid and Semi Rigid components improve crash energy management through the cabin opening Crash Safety Performance Door Ring Crash Management
USIBOR 1500 HSS 590 HSS 980 HSS 780
The Door Ring components with the Floor components better balance and distribute crash energy in a controlled manner IIHS Small Overlap Test IIHS Small Overlap Achievement
[ Crash Video ] IIHS Small Overlap Test IIHS Official SOT Achievement IIHS Acceptable Structure = Acceptable
Acceptable
Rating
10/9/2014
Different wheel fracture mode and fracture timing IIHS Small Overlap Test Overall Crash Safety Performance
Item Mode 14M TL 15M TLX
Overall 4-Star Overall 5-Star NCAP
4 X Roof Crush Good Good Roof Crush Roof Crush IIHS 4x Curb weight 4x Curb weight
Top Safety Pick Side Impact
SICE Good Good Side Crash Side Crash SUV 50 km/h SUV 50 km/h Rear Crash Protection
Good Good Base TSP Base (whiplash) TSP Base Rear Crash Rear Crash Active Head rest Active Head rest
Front Crash Good Accpt • Small Overlap Test Small Small • 40% ODB Overlap Test Overlap Test
15M TLX: Crash + TSP Crash Avoidance ADV: CMBS + Tech: FCW Avoidance GTR HEAD GTR HEAD Pedestrian Protection HIC ≤ 1000 66% HIC ≤ 1000 66% HIC ≤ 1700 100% HIC ≤ 1700 100% Summary THANK YOU FOR YOUR ATTENTION