2015 Acura TLX Body Structure Review Aron Madsen Principal Engineer Cabin Technical Expert Upper Body Design
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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 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 .